LI-Series Install-Operation Manual Ver1 - 0 For Sept 07 SRVC

ULTRATREAT LI-SERIES
Installation and Operation Manual

Training Version 1.0
This manual covers

the following models:

- UltraSoft LI-Series
Water Softeners

- UltraSand LI-Series
Multimedia Depth
Filters

- UltraCarb LI-Series
Activated Carbon
Filters
UltraSoft LI-Series Water Softeners

UltraSand LI-Series Depth Filters
UltraCarb LI-Series AC Filters
ULTRATREAT LI-SERIES Installation and Operation
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Call NGES: (630) 848-3387 Copyright 2007 Nalco Company
Table of Contents Page
Section 1: Introduction
1.1 About ULTRATREAT Service ................................................ 7

1.2 About this Manual ................................................................... 7
Section 2: Technology Overview

2.1 Water Fundamentals ............................................................... 8
2.1.1 Water Impurities............................................................................... 8
2.1.2 Water Hardness.............................................................................. 18
2.2 The Filtration Process........................................................... 22

2.2.1 Definitions....................................................................................... 22
2.2.2 Multi Media Filtration ..................................................................... 22
2.2.3 Activated Carbon Filtration........................................................... 23
2.3 The Softening Process.......................................................... 24

2.3.1 Definitions....................................................................................... 24
2.3.2 Lime-Soda Softening ..................................................................... 24
2.3.3 Ion Exchange Softening................................................................ 25
2.3.4 Regeneration Salt .......................................................................... 26
2.4 Principles of Ion Exchange Resin ........................................ 27

2.4.1 Types of Resin ............................................................................... 28
2.4.2 Resin Properties ............................................................................ 28
2.4.3 Resin Operating Capacity ............................................................. 29
2.4.4 Resin Operating Parameters ........................................................ 31
2.4.5 Resin Brand Equivalents .............................................................. 32
2.4.6 Resin Life Expectancy................................................................... 32

Section 2: Technology Overview continued
2.5 The Filtration Operating Sequence ...................................... 33

2.5.1 Service ............................................................................................ 33
2.5.2 Backwash........................................................................................ 33
2.5.3 Slow Settling Rinse .................................................................... 34
2.5.4 Fast Rinse ...................................................................................... 34
2.5.5 Return to Service .......................................................................... 34
2.5.6 General Design Parameters.......................................................... 35
2.5.7 System Specifications Multimedia Filters................................ 35
2.5.8 System Specifications Activated Carbon Filters .................... 35
2.6 The Softener Operating Sequence ....................................... 36

2.6.1 Service ............................................................................................ 36
2.6.2 Backwash........................................................................................ 36
2.6.3 Slow Rinse / Brine Eduction ......................................................... 36
2.6.4 Fast Rinse ...................................................................................... 37
2.6.5 Return to Service .......................................................................... 37
2.6.6 General Design Parameters.......................................................... 37
2.6.7 Softener System Specifications................................................... 38
Section 3: Installation and Start-Up

3.1 STEP 1 EQUIPMENT DESIGN CHECK-LIST ...................... 41
3.1.1 Water Source: City / Well ............................................................. 41
3.1.2 Water Source Line Pressure......................................................... 41
3.1.3 Water Source Temperature........................................................... 42
3.1.4 Backwash Drain Flow Size............................................................ 43
3.1.5 Electrical Supply ............................................................................ 43
3.1.5 Manual Isolation Valves ................................................................ 43
3.2 STEP 2 PRE-INSTALLATION CHECK-LIST ....................... 44

Section 3: Installation and Start-Up continued

3.3 STEP 3 UNPACKING .......................................................... 45
3.3.1 Unpacking Checklists ........................................................ 46
3.3.1.1 TWIN Water Softeners............................................ 47
3.3.1.2 SIMPLEX Water Softeners ...................................... 49
3.3.1.3 DUPLEX Water Softeners ....................................... 51
3.3.1.4 MMF & AC Filter Systems ....................................... 54
3.4 STEP 4 LOCATING ............................................................. 55

3.4.1 Locating Softener / Filter System ........................................ 56
3.5 STEP 5 VALVE & PIPING INSTALLATION......................... 57

3.5.1 TWIN Water Softener Valve & Piping ................................... 58
3.5.2 TWIN Water Softener Injector Assembly .............................. 61
3.5.3 TWIN Water Softener Drain Line Flow Controller .................. 62
3.5.4 SIMPLEX Water Softener Valve & Piping ............................. 64
3.5.5 SIMPLEX Water Softener Injector Assembly ........................ 66
3.5.6 SIMPLEX Water Softener Drain Line Flow Controller ............ 67
3.5.7 DUPLEX 1.0 & 1.5 Water Softener Valve & Piping .............. 70
3.5.8 DUPLEX 1.0 & 1.5 Water Softener Injector Assembly ......... 74
3.5.9 DUPLEX 1.0 & 1.5 Water Softener DLFC ........................... 75
3.5.10 DUPLEX 2.0 & 3.0 Water Softener Valve & Piping ............ 77
3.5.11 DUPLEX 2.0 & 3.0 Water Softener Injector Assembly ....... 81
3.5.12 DUPLEX 2.0 & 3.0 Water Softener DLFC.......................... 82
3.5.13 MMF & AC FILTERS Valve & Piping ................................... 86
3.5.14 MMF & AC FILTERS Drain Line Flow Controller .................. 88
3.6 STEP 6 MEDIA LOADING ................................................... 90

3.6.1 Multi-Media & Activated Carbon Filters................................ 92
3.6.2 Water Softeners ................................................................ 93
3.7 STEP 7 INSTALLATION CHECKLIST................................. 94

Section 3: Installation and Start-Up continued

3.8 STEP 8 PROGRAMMING & COMMISSIONING .................. 96
3.8.1 Commissioning Guide ................................................ 99-100
3.8.2 Simplex (Single) Units ..................................................... 101
3.8.3 Twin Units ...................................................................... 103
3.8.4 Duplex Alternating Units .................................................. 105
Section 4: Maintenance
4.1 Preventative Maintenance .................................................. 111
4.1.1 General Maintenance Guideline ................................................. 111
Section 5: Troubleshooting
5.1 Troubleshooting.................................................................. 112
5.1.1 Troubleshooting Protocol........................................................... 112
5.1.2 Operational Problems ................................................................. 113
5.1.3 Troubleshooting Matrix .............................................................. 114
5.1.4 PSR Service Report Elution Study Report ............................ 116
5.1.4.1 Elution Study Instructions ............................................. 116
5.1.4.2 Elution Study Cover Page ............................................. 117
5.1.4.3 Elution Study Survey Page ............................................ 118
5.1.4.4 Elution Study Data Page ................................................ 119
5.1.4.5 Elution Study Resource Page #1 .................................. 120
5.1.4.6 Elution Study Resource Page #2 .................................. 121
5.1.5 Manufacturer Spare Parts Lists ................................................ 122
Section 5: Appendices
A Glossary of Terms & Definitions ........................................ 124
B Limited Warranty................................................................. 127
C-G Nalco Equipment Specifications................................. 128-151
H-N FLECK Service & Programming Manuals................... 128-151

Section 1: Introduction
1.1 About ULTRATREAT Service

Nalco customers and water treatment market factors are changing the
environment that we serve. With only pure chemical sales it will be difficult for
Nalco to meet the expected long-term growth targets. Customers expect the
most efficient solutions. Increasingly these solutions are integrated offerings of
chemicals, equipment and services: a total solutions package.
The key to success is to be seen by the customer providing value and the
intellectual capacity to integrate the total customer solution. A strong capability in
industrial equipment and sellable services wrapped around the equipment would
provide opportunities for sustainable and profitable growth in alignment with
Nalcos growth objectives.
The Nalco equipment product offering is heavily weighted towards chemical

application and related services (feed, control, automation). The sale of
pretreatment equipment and services wrapped around pretreatment equipment is
the fastest growing segment of the Nalco product offering but is far from meeting
potential.
Broader equipment and service opportunities are found in all of our core
chemical application areas. Installation and servicing of high efficiency filtration
equipment is an excellent fit and offering through Nalco Services to customers in
order to provide them the total solutions package.
1.2 About this Manual

This manual is a simple, step-by-step description of what you need to do to get
an LI-Series Softener or Filter up and running in the shortest amount of time.
Please keep in mind that your Nalco Sales Representative has already done
some of the pre-installation checklist work for you the Nalco Services
representative. Dont hesitate to contact the Nalco Sales Representative if you
have a question or a problem, as they should be helpful in addressing any
specific questions or needs you may have concerning the system the customer
has purchased. And always remember
! Additional help is available at NGES HELP DESK 630-848-3387


2.1 Water Fundamentals
2.1.1 Water Impurities
Abundant supplies of fresh water are essential to the development of industry.

Enormous quantities are required for the cooling of products and equipment, for
process needs, for boiler feed, and for sanitary and potable water supply.
The Hydrologic Cycle
Industry is a small participant in the global water cycle .The finite amount of water
on the planet participates in a very complicated recycling scheme that provides
for its reuse. This recycling of water is termed the "Hydrologic Cycle."
Evaporation under the influence of sunlight takes water from a liquid to a

gaseous phase. The water may condense in clouds as the temperature drops in
the upper atmosphere. Wind transports the water over great distances before
releasing it in some form of precipitation. As the water condenses and falls to the
ground, it absorbs gases from the environment. This is the principal cause of acid
rain and acid snow.
Water: Universal Solvent
Pure water (H20) is colorless, tasteless, and odorless. It is composed of hydrogen

and oxygen. Because water becomes contaminated by the substances with
which it comes into contact, it is not available for use in its pure state. To some
degree, water can dissolve every naturally occurring substance on the earth.
Because of this property, water has been termed a "universal solvent."
Although beneficial to mankind, the solvency power of water can pose a major
threat to industrial equipment. Corrosion reactions cause the slow dissolution of
metals by water. Deposition reactions, which produce scale on heat transfer
surfaces, represent a change in the solvency power of water as its temperature is
varied. The control of corrosion and scale is a major focus of water treatment
technology.


2.1.1 Water Impurities continued
Water impurities include dissolved and suspended solids. Calcium bicarbonate is

a soluble salt. A solution of calcium bicarbonate is clear, because the calcium
and bicarbonate are present as atomic sized ions, which are not large enough to
reflect light. Some soluble minerals impart a color to the solution. Soluble iron
salts produce pale yellow or green solutions; some copper salts form intensely
blue solutions.
Although colored, these solutions are clear. Suspended solids are substances
that are not completely soluble in water and are present as particles. These
particles usually impart a visible turbidity to the water. Dissolved and suspended
solids are present in most surface waters.
Seawater is very high in soluble sodium chloride; suspended sand and silt make
it slightly cloudy. An extensive list of soluble and suspended impurities found in
water is given in Table 2.1.1.1 below.
Table 2.1.1.1: Common impurities found in fresh water.
Constituent Chemical Formula Difficulties Caused Means of Treatment

imparts unsightly appearance to
water; deposits in water lines,
non-expressed in coagulation, settling, and
Turbidity process equipment, etc.;
analysis as units filtration
interferes with most process
uses
chief source of scale in heat
softening; demineralization;
calcium and magnesium exchange equipment, boilers,
internal boiler water
Hardness salts, expressed as pipe lines, etc.; forms curds with
treatment; surface active
CaCO3 soap, interferes with dyeing,
agents
etc.
foam and carryover of solids lime and lime-soda
bicarbonate(HCO3-), with steam; embrittlement of softening; acid treatment;
carbonate (CO32-), and boiler steel; bicarbonate and hydrogen zeolite softening;
Alkalinity -
hydroxide(OH ), carbonate produce CO2 in demineralization
expressed as CaCO3 steam, a source of corrosion in dealkalization by anion
condensate lines exchange
Free Mineral H2SO4 , HCI. etc.,

corrosion neutralization with alkalies
Acid expressed as CaCO3
corrosion in water lines,

Carbon aeration, deaeration,
CO2 particularly steam and
Dioxide neutralization with alkalies
condensate lines

hydrogen ion
pH varies according to acidic or
concentration defined as: pH can be increased by
alkaline solids in water; most
PH 1 alkalies and decreased by
pH = log natural waters have a pH of 6.0-
acids
+
[H ] 8.0
adds to solids content of water,
but in itself is not usually demineralization, reverse
Sulfate SO42- significant, combines with osmosis, electrodialysis,
calcium to form calcium sulfate evaporation
scale
adds to solids content and demineralization, reverse
Chloride Cl - increases corrosive character of osmosis, electrodialysis,
water evaporation
adds to solids content, but is
not usually significant
demineralization, reverse
industrially: high concentrations
Nitrate NO3- osmosis, electrodialysis,
cause methemoglobinemia in
evaporation
infants; useful for control of
boiler metal embrittlement
cause of mottled enamel in adsorption with magnesium
- teeth; also used for control of hydroxide, calcium
Fluoride F
dental decay: not usually phosphate, or bone black;
significant industrially alum coagulation
adds to solids content of water:
when combined with OH-,
Sodium Na+ osmosis, electrodialysis,
causes corrosion in boilers
evaporation
under certain conditions
hot and warm process
removal by magnesium
scale in boilers and cooling
salts; adsorption by highly
water systems; insoluble turbine
Silica SiO2 basic anion exchange
blade deposits due to silica
resins, in conjunction with
vaporization
osmosis, evaporation
discolors water on precipitation; aeration; coagulation and
source of deposits in water filtration; lime softening;
Fe2+ (ferrous)
Iron lines, boilers. etc.; interferes cation exchange; contact
Fe3+ (ferric)
with dyeing, tanning, filtration; surface active
papermaking, etc. agents for iron retention
Manganese Mn2+ same as iron same as iron
usually present as a result of
floc carryover from clarifier; can
improved clarifier and filter
Aluminum AI3+ cause deposits in cooling
operation
systems and contribute to
complex boiler scales
corrosion of water lines, heat
deaeration; sodium sulfite;
Oxygen O2 exchange equipment, boilers,
corrosion inhibitors
return lines, etc.
Hydrogen cause of "rotten egg" odor; aeration; chlorination; highly
H2S
Sulfide corrosion basic anion exchange
corrosion of copper and zinc cation exchange with
Ammonia NH3 alloys by formation of complex hydrogen zeolite;
soluble ion chlorination; deaeration
Dissolved refers to total amount of lime softening and cation
none
Solids dissolved matter, determined by exchange by hydrogen

evaporation; high zeolite; demineralization,
concentrations are reverse osmosis,
objectionable because of electrodialysis, evaporation
process interference and as a
cause of foaming in boilers
refers to the measure of
undissolved matter, determined subsidence; filtration,
Suspended
none gravimetrically; deposits in heat usually preceded by
Solids
exchange equipment, boilers, coagulation and settling
water lines, etc.
refers to the sum of dissolved
see "Dissolved Solids" and
Total Solids none and suspended solids,
"Suspended Solids"
determined gravimetrically
Surface Water
The ultimate course of rain or melting snow depends on the nature of the terrain
over which it flows. In areas consisting of hard packed clay, very little water
penetrates the ground. In these cases, the water generates "runoff". The runoff
collects in streams and rivers. The rivers empty into bays and estuaries, and the
water ultimately returns to the sea, completing one major phase of the hydrologic
cycle.
As water runs off along the surface, it stirs up and suspends particles of sand
and soil, creating silt in the surface water. In addition, the streaming action
erodes rocky surfaces, producing more sand. As the surface water cascades
over rocks, it is aerated. The combination of oxygen, inorganic nutrients leached
from the terrain, and sunlight supports a wide variety of life forms in the water,
including algae, fungi, bacteria, small crustaceans, and fish.
Often, river beds are lined with trees, and drainage areas feeding the rivers are
forested. Leaves and pine needles constitute a large percentage of the biological
content of the water. After it dissolves in the water, this material becomes a major
cause of fouling of ion exchange resin used in water treatment.
The physical and chemical characteristics of surface water contamination vary

considerably over time. A sudden storm can cause a dramatic short-term change
in the composition of a water supply. Over a longer time period, surface water
chemistry varies with the seasons. During periods of high rainfall, high runoff
occurs. This can have a favorable or unfavorable impact on the characteristics of
the water, depending on the geochemistry and biology of the terrain.


Surface water chemistry also varies over multi year or multi-decade cycles of
drought and rainfall. Extended periods of drought severely affect the availability
of water for industrial use. Where rivers discharge into the ocean, the incursion of
salt water up the river during periods of drought presents additional problems.
Industrial users must take surface water variability into account when designing
water treatment plants and programs.
Groundwater
Water that falls on porous terrains, such as sand or sandy loam, drains or
percolates into the ground. In these cases, the water encounters a wide variety of
mineral species arranged in complex layers, or strata. The minerals may include
granite, gneiss, basalt, and shale. In some cases, there may be a layer of very
permeable sand beneath impermeable clay. Water often follows a complex three-
dimensional path in the ground. The science of groundwater hydrology involves
the tracking of these water movements.
Table 2.1.1.2: A comparison of surface water and groundwater characteristics.
Characteristic Surface Water Ground Water

Turbidity high Low
Dissolved minerals low-moderate High
Biological content high Low
Temporal variability very high Low
In contrast to surface supplies, groundwaters are relatively free from suspended

contaminants, because they are filtered as they move through the strata. The
filtration also removes most of the biological contamination. Some groundwaters
with a high iron content contain sulfate-reducing bacteria. These are a source of
fouling and corrosion in industrial water systems.
Groundwater chemistry tends to be very stable over time. A groundwater may

contain an undesirable level of scale forming solids, but due to its fairly
consistent chemistry it may be treated effectively.


Mineral Reactions
As groundwater encounters different minerals, it dissolves them according to

their solubility characteristics. In some cases chemical reactions occur,
enhancing mineral solubility.
A good example is the reaction of groundwater with limestone. Water percolating

from the surface contains atmospheric gases. One of these gases is carbon
dioxide, which forms carbonic acid when dissolved in water. The decomposition
of organic matter beneath the surface is another source of carbon dioxide.
Limestone is a mixture of calcium and magnesium carbonate. The mineral, which
is basic, is only slightly soluble in neutral water. The slightly acidic groundwater
reacts with basic limestone in a neutralization reaction that forms a salt and a
water of neutralization.
The salt formed by the reaction is a mixture of calcium and magnesium

bicarbonate. Both bicarbonates are quite soluble. This reaction is the source of
the most common deposition and corrosion problems faced by industrial users.
The calcium and magnesium (hardness) form scale on heat transfer surfaces if
the groundwater is not treated before use in industrial cooling and boiler systems.
In boiler feedwater applications, the thermal breakdown of the bicarbonate in the
boiler leads to high levels of carbon dioxide in condensate return systems. This
can cause severe system corrosion.
Structurally, limestone is porous. That is, it contains small holes and channels
called "interstices". A large formation of limestone can hold vast quantities of
groundwater in its structure. Limestone formations that contain these large
quantities of water are called aquifers, a term derived from Latin roots meaning
water bearing.
If a well is drilled into a limestone aquifer, the water can he withdrawn

continuously for decades and used for domestic and industrial applications.
Unfortunately, the water is very hard, due to the neutralization/dissolution
reactions described above. This necessitates extensive water treatment for most
uses.


Chemical Reactions
Numerous chemical tests must be conducted to ensure effective control of a

water treatment program. Because of their significance in many systems, three
tests, pH, alkalinity, and silica, are discussed here as well.
pH Control
The "p" function is used in chemistry to handle very small numbers. It is the
negative logarithm of the number being expressed. Water that has 10-7 gram
equivalents per liter of hydrogen ions is said to have a pH of 7. Thus, a neutral
solution exhibits a pH of 7. Table 2.1.1.3 lists the concentration of H+ over 14
orders of magnitude. As it varies, the concentration of OH - must also vary, but in
the opposite direction, such that the product of the two remains constant.
Good pH control is essential for effective control of deposition and corrosion in

many water systems. Therefore, it is important to have a good understanding of
the meaning of pH and the factors that affect it.
Pure H2O exists as an equilibrium between the acid species, H+ (more correctly
expressed as a protonated water molecule, the hydronium ion, H30+) and the
hydroxyl radical, OH -. In neutral water the acid concentration equals the
hydroxyl concentration and at room temperature they both are present at 10-7
gram equivalents (or moles) per liter.
Confusion regarding pH arises from two sources:
the inverse nature of the function

the pH meter scale
It is important to remember that as the acid concentration increases, the pH

value decreases (see Table 2.1.1.4 on the next page).


Table 2.1.1.3: pH relationship
H+ H+ OH - OH -
Concentration Concentration, Concentration, Concentration,
pH Exponential Normality Normality Exponential pOH -
Notation Notation
(gram moles/L) (gram moles/L)
0 100 1 0.00000000000001 10-14 14
1 10-1 0.1 0.0000000000001 10--13 13
-2 -12
2 10 0.01 0.000000000001 10- 12
-3 -11
3 10 0.001 0.00000000001 10 11
4 10-4 0.0001 0.0000000001 10-10 10
-5 -9
5 10 0.00001 0.000000001 10 9
-6 -8
6 10 0.000001 0.00000001 10 8
-7 -7
7 10 0.0000001 0.0000001 10 7
-8 -6
8 10 0.00000001 0.000001 10 6
9 10-9 0.000000001 0.00001 10-5 5
-10 -4
10 10 0.0000000001 0.0001 10 4
-11 -3
11 10 0.00000000001 0.001 10 3
12 10-12 0.000000000001 0.01 10-2 2
-13 -1
13 10 0.0000000000001 0.1 10 1
-14 0
14 10 0.00000000000001 1 10 0
Table 2.1.1.4: Comparative pH levels of common solutions.
12 OH - alkalinity 500 ppm as CaCO3

9 strong base anion exchanger effluents
8 phenolphthalein end point
7 neutral point at 25 C
6
5 methyl orange end point
4 FMA 4 ppm as CaCO3


The pH meter can be a source of confusion, because the pH scale on the meter
is linear, extending from 0 to 14 in even increments. Because pH is a logarithmic
function, a change of I pH unit corresponds to a 10 fold change in acid
concentration. A decrease of 2 pH units represents a 100 fold change in acid
concentration.
Alkalinity
Alkalinity tests are used to control lime-soda softening processes and boiler
blowdown and to predict the potential for calcium scaling in cooling water
systems. For most water systems, it is important to recognize the sources of
alkalinity and maintain proper alkalinity control.
Carbon dioxide dissolves in water as a gas. The dissolved carbon dioxide reacts
with solvent water molecules and forms carbonic acid according to the following
reaction:
CO2 + H2O = H2CO3
Only a trace amount of carbonic acid is formed, but it is acidic enough to lower
pH from the neutral point of 7. Carbonic acid is a weak acid, so it does not lower
pH below 4.3. However, this level is low enough to cause significant corrosion of
system metals.
If the initial loading of CO2 is held constant and the pH is raised, a gradual
transformation into the bicarbonate ion HCO3- occurs.
The transformation is complete at pH 8.3. Further elevation of the pH forces a

second transformation into carbonate, CO33-2. The three species carbonic acid,
bicarbonate, and carbonate can be converted from one to another by means of
changing the pH of the water.
Variations in pH can be reduced through "buffering" the addition of acid (or

caustic). When acid (or caustic) is added to water containing
carbonate/bicarbonate species, the pH of the system does not change as quickly
as it does in pure water. Much of the added acid (or caustic) is consumed as the
carbonate/bicarbonate (or bicarbonate/carbonic acid) ratio is shifted.


Alkalinity is the ability of natural water to neutralize acid (i.e., to reduce the pH
depression expected from a strong acid by the buffering mechanism mentioned
above). Confusion arises in that alkaline pH conditions exist at a pH above 7,
whereas alkalinity in natural water exists at a pH above 4.4.
Alkalinity is measured by a double titration; acid is added to a sample to the

Phenolphthalein end point (pH 8.3) and the Methyl Orange end point (pH 4.4).
Titration to the Phenolphthalein end point (the P-alkalinity) measures OH- and
1/2 CO3-2; titration to the Methyl Orange end point (the M-alkalinity) measures
OH -, CO3-2 and HCO3 .
Silica
When not properly controlled, silica forms highly insulating, difficult to remove
deposits in cooling systems, boilers, and turbines. An understanding of some of
the possible variations in silica testing is valuable.
Most salts, although present as complicated crystalline structures in the solid

phase, assume fairly simple ionic forms in solution. Silica exhibits complicated
structures even in solution.
Silica exists in a wide range of structures, from a simple silicate to a complicated

polymeric material. The polymeric structure can persist when the material is
dissolved in surface waters.
The size of the silica polymer can be substantial, ranging up to the colloidal state.
Colloidal silica is rarely present in groundwaters. It is most commonly present in
surface waters during periods of high runoff.
The polymeric form of silica does not produce color in the standard molybdate
based colorimetric test for silica. This form of silica is termed "nonreactive". The
polymeric form of silica is not thermally stable and when heated in a boiler
reverts to the basic silicate monomer, which is reactive with molybdate.


As a result, molybdate testing of a boiler feedwater may reveal little or no silica,

while boiler blowdown measurements show a level of silica that is above control
limits. High boiler water silica and low feedwater values are often a first sign that
colloidal silica is present in the makeup.
One method of identifying colloidal silica problems is the use of atomic emission
or absorption to measure feedwater silica. This method, unlike the molybdate
chemistry, measures total silica irrespective of the degree of polymerization.
2.1.2 Water Hardness
Water becomes hard by being in contact with soluble, divalent, metallic cations
(positive ions having a valence of 2). The two main cations that cause water
hardness are calcium (Ca+2) and magnesium (Mg+2). Calcium is dissolved in
water as it passes over and through limestone deposits. Magnesium is dissolved
as water passes over and through dolomite and other magnesium bearing
formations.
Because groundwater is in contact with these geologic formations for a longer

period of time than surface water, groundwater is usually harder than surface
water. Although strontium, aluminum, barium, iron, manganese, and zinc also
cause hardness in water, they are not usually present in large enough
concentrations to contribute significantly to total hardness.
Hardness was originally defined as the capacity of water to precipitate soap.

Calcium and magnesium precipitate soap, forming a curd which causes bathtub
ring and dingy laundry (yellowing, graying, loss of brightness, and reduced life of
washable fabrics), and feels unpleasant on the skin (red, itchy, or dry skin).
To counteract these problems, synthetic detergents have been developed. These

detergents have additives known as sequestering agents that tie-up the
hardness ions so they cannot form the troublesome precipitates. Although
synthetic detergents overcome these problems, both soap and detergent are
wasted by hardness.


2.1.2 Water Hardness continued
Hard water forms scale, usually calcium carbonate, which causes a variety of
problems. Left to dry on the surface of glassware, silverware, and plumbing
fixtures (shower doors, faucets and sink tops), hard water leaves unsightly scale,
called water spots.
Scale that forms on the inside of water pipes eventually reduces the water pipes
carrying capacity. Scale that forms within appliances, pumps, valves, and water
meters causes wear on moving parts. When hard water is heated, scale forms
much faster. This creates an insulation problem inside boilers, water heaters, and
hot-water lines and increases heating costs.
Water hardness is, unfortunately, expressed in several different units, and thus it
is often necessary to convert from one unit to another when making calculations.
The most commonly used units include grains per gallon (gpg), parts per million
(ppm), and milligrams per liter (mg/L).
The grain per gallon is based on the old English system of weights and
measures. It is based on the average weight of a dry kernel of grain (or wheat).
The part per million is a weight to weight ratio. For example, one ppm of calcium
means 1 pound of calcium in 1 million pounds of water, or 1 gram of calcium in 1
million grams of water. Since pure water weighs 1000 grams per liter, the mg/L
is the same as the ppm in the dilute solutions present in most raw and treated
water.
To convert To Multiply by
Grains per gallon Milligrams per liter 17.12
Milligrams per liter Grains per gallon 0.05841
Since calcium carbonate is one of the more common causes of hardness, total
hardness is usually reported in terms of calcium carbonate concentration (mg/L
or ppm as CaCO3), using either of two methods:
(a) Hardness caused by calcium is called calcium hardness, regardless

of the salts associated with it.
(b) Carbonate hardness is primarily caused by the carbonate and

bicarbonate salts of calcium and magnesium.


(a) Hardness caused by calcium is called calcium hardness, regardless of the

salts associated with it. Likewise, hardness caused by magnesium is
called magnesium hardness. Since calcium and magnesium are normally
the only significant minerals that cause hardness, it is generally assumed
that:
Total Hardness = Calcium Hardness + Magnesium Hardness

(mg/L as CaCO3) (mg/L as CaCO3) (mg/L as CaCO3)
= 2.50 X Calcium concentration + 4.12 X Magnesium concentration

+2 +2
(mg/L as Ca ) (mg/L as Mg )
(b) Carbonate hardness is primarily caused by the carbonate and bicarbonate

salts of calcium and magnesium. Non-carbonate hardness is a measure of
calcium and magnesium salts other than carbonate and bicarbonate salts,
such as calcium sulfate, CaSO4, or magnesium chloride, MgCl2. Total
hardness is expressed as the sum of the carbonate hardness and non-
carbonate hardness.
Total hardness = Carbonate hardness + Non-carbonate hardness

(mg/L as CaCO3) (mg/L as CaCO3) (mg/L as CaCO3)
The amount of carbonate and non-carbonate hardness depends on the

alkalinity of the water. When a laboratory reports a value for total
hardness of, for instance, 150 mg/l as CaCO3, this indicates that the
combined effect of the different hardness causing agents is the same as if
the water contained exactly 150 mg/l of CaCO3.
The degree of hardness consumers consider objectionable will vary, depending

both on the water and the degree of hardness to which consumers have become
accustomed. The following table shows a classification of water hardness:
Hardness mg/L (ppm) as CaCO3

Soft 0 to 75
Moderate 75 to 150
Hard 150 to 300
Very Hard Above 300


The degree of hardness acceptable for a finished water varies with the consumer
or industry served. In 1968, the American Water Works Association (AWWA)
established a water quality goal for total hardness of 80 to 100 mg/l as calcium
carbonate.
It has often been proposed that ideally water should have a total hardness of 75
to 85 mg/l (as CaCO3) and a magnesium hardness of not more than 40 mg/l as
CaCO3 to minimize magnesium hydroxide scaling at elevated temperatures,
although the actual magnesium concentration that can be present before
precipitation of magnesium salt is a function of the pH of the finished water.
In recent years, many cities have allowed the hardness in finished water to
approach 110 to 150 mg/L to reduce chemical costs and sludge production. The
general use of synthetic detergents has reduced the importance of hardness for
soap consumption; however, industrial requirements for a higher-quality feed
water for high pressure boilers and cooling towers have generally increased.
Courtesy of the U.S. Geological Survey, Report 78-200


2.2 The Filtration Process
2.2.1 Definition
Filtration is simply the process of removing contaminants from water by trapping

or adsorbing them.
2.2.2 Multi-Media Filtration
Multi-Media or Depth filters (Nalco UltraSand Filters) use three layers of media
(selected for particle size, uniformity and specific gravity) to remove particulate
material (reduce the turbidity) from water as it flows through a filter bed.
Unfiltered water first contacts the coarsest, lightest media that removes the
largest particles and retains them at the top of the filter. The subsequent media
layers progressively get finer and heavier in order to trap smaller and smaller
particles as they contact the lower layers.
This multiple-media approach uses the full depth of the filter bed to trap and hold
particles, rather than using only the top layer found in single-media sand filters.
This is where the name depth filter comes from. During the service cycle,
contaminants are continually removed until the layers of media reach their
maximum holding capacity. This is usually measured by an increase in the
pressure drop across the filter. When the pressure drop increases approximately
5-10 psi greater than a predetermined clean filter reading, the filter is
backwashed to flush the trapped particles from the media.
A backwash consists of a rapid upflow of water through the media layers.

Particulates are flushed from the bed as the media expands and the granules
scour each other. Next a downflow rinse helps restratify the layers and rinse the
media before the system returns to service.
2.2.3 Activated Carbon Filtration
Activated Carbon filters (Nalco UltraCarb Filters) use high-quality granular

activated carbon to adsorb and filter water. These coal-based carbons provide
the high capacity and the durability to handle abrasion from backwashing. The
activated carbon produces an exceptionally large internal surface area with
controlled pore sizes that effectively adsorb a broad range of high or low-
molecular-weight organic compounds.


2.2 The Filtration Process
2.2.3 Activated Carbon Filtration continued
Chlorine is rapidly removed while maintaining high flow rates through the filter
bed. Organic materials adsorption is generally slower. During the service cycle,
the carbon media can become compacted or plugged with suspended solids.
The filter then needs to be backwashed. In general, activated carbon filters are
not backwashed as frequently as multi-media filters, which helps minimize
carbon breakage. The carbon will eventually be exhausted and need to be
replaced every several months to several years, depending on the type of
contaminants being removed.

2.3 The Softening Process

2.3.1 Definition
The process of removing hardness from water is called softening. Hardness is

mainly caused by the presence of calcium and magnesium salts. These
substances are dissolved from deposits through which the water percolates. The
length of time that water is in contact with the hardness-producing material is one
factor that determines how much hardness there is in the raw water.
The function of a water softener is to reduce the hardness in feedwater using ion
exchange resin. Hardness, if not removed, will create scale on reverse osmosis
membranes, water heaters, boilers, and other equipment.
2.3.2 Lime-Soda Softening
Precipitation softening accomplished at ambient temperatures is referred to as

lime-soda softening or cold-lime softening. Precipitation softening processes are
used to reduce raw water hardness, alkalinity, silica, and other constituents. This
helps prepare water for direct use as cooling tower makeup or as a first-stage
treatment followed by ion exchange for boiler makeup or process use.
The water is treated with lime or a combination of lime and soda ash (carbonate
ion). These chemicals react with the hardness and natural alkalinity in the water
to form insoluble compounds. The compounds precipitate and are removed from
the water by sedimentation and, usually, filtration. Waters with moderate to high
hardness and alkalinity concentrations (150-500 ppm as CaCO3) are often
treated in this fashion.
In almost every raw water supply, hardness is present as calcium and

magnesium bicarbonate, often referred to as carbonate hardness or temporary
hardness. These compounds result from the action of acidic, carbon dioxide
laden rainwater on naturally occurring minerals in the earth, such as limestone.
Hardness may also be present as a sulfate or chloride salt, referred to as

noncarbonate or permanent hardness. These salts are caused by mineral acids
present in rainwater or the solution of naturally occurring acidic minerals.

2.3 The Softening Process

2.3.2 Lime-Soda Softening continued
The significance of "carbonate" or "temporary" hardness as contrasted to

"noncarbonate" or "permanent" hardness is that the former may be reduced in
concentration simply by heating. Reduction of noncarbonate hardness, by
contrast, requires chemical addition. A combination of lime and soda ash, along
with coagulant and flocculant chemicals, is added to raw water to promote a
precipitation reaction. This allows softening to take place.
2.3.3 Ion Exchange Softening
In a conventional ion exchange water softener, the pressure vessel contains high
quality strong acid cation resin in the sodium form that removes hardness, i.e.
calcium, magnesium, and other cations removed by the resin are replaced with
sodium ions. Resin captures the hardness ions as the hard water flows through
the softener tank. When the resin becomes filled with these ions, the resin is
regenerated by a salt solution prepared in the brine tank.
The resin has a fixed capacity based on the pounds of salt used per cubic foot of
resin during regeneration. Flow rate, TDS, and other factors will dictate the actual
capacity of the resin. When the capacity is exceeded, the resin will allow the
hardness ions to pass through the unit. Before the capacity is exceeded, the unit
is removed from service and regenerated with a solution of sodium chloride
(brine). Completion of the regeneration steps allows the water softener to be
returned to the service mode.
Softeners can operate in single, parallel or alternating modes. Single softeners

are usually used in applications that do not require a constant availability of soft
water. These units regenerate when treated water is not in high demand. During
these periods unsoftened water is bypassed to service. Applications requiring a
continuously available supply of soft water typically require more than one resin
tank.
These tanks can either be arranged in parallel or alternating modes. When

operating in parallel, all the installed tanks are online. When a regenerating tank
completes its recharge and rinse cycle, it is immediately returned to service.
Alternating systems, like parallel configurations, are also capable of providing a
continuous supply of softened water. In alternating systems, a minimum of one
resin tank is always regenerating or being held in a standby position so it is ready
to return to service when the online tank is filled with hardness ions. Typically,
alternating systems contain between two and four tanks, with one in a
regeneration/standby state.

2.3 The Softening Process continued
2.3.4 Regeneration Salt


2.4 Principles of Ion Exchange Resin
An ion exchange resin is an insoluble matrix (or support structure) normally in the
form of small (1-2 mm diameter) beads, usually white or yellowish, fabricated
from an organic polymer substrate. The material has highly developed structure
of pores on the surface of which are sites with easily trapped and released ions.
The trapping of ions takes place only with simultaneous releasing of other ions;
thus the process is called ion exchange. There are multiple different types of ion
exchange resin which are fabricated to selectively prefer one or several different
types of ions.
Ion exchange resins are widely used in different separation, purification, and
decontamination processes. The most common examples are water softening
and water purification. In many cases ion exchange resins were introduced in
such processes as a more flexible alternative to the use of natural or artificial
zeolites.
Most typical ion exchange resins are based on crosslinked polystyrene. The
required active groups can be introduced after polymeration, or substituted
monomers can be used. For example, the crosslinking is often achieved by
adding 0.5-25% of divinyl benzene to styrene at the polymerisation process.
Non-crosslinked polymers are used only rarely because they are less stable.
Crosslinking decreases ion exchange capacity of the resin and prolongs the time
needed to accomplish the ion exchange processes. Particle size also influences
the resin parameters; smaller particles have larger outer surface, but cause
larger head loss in the colum processes.
Besides of bead-shaped materials, ion exchange resins are produced as

membranes. The membranes made of highly cross-linked ion exchange resins
that allow passage of ions but not of water are used for electrodialysis.


2.4.1 Types of Resin
Regardless of brand, the core principles of ion exchange resin remain the same.
There are 4 main types of resin, each with their own function:
Strong acid cation (SAC)

Weak acid cation (WAC)
Strong base anion (SBA)
Weak base anion (WBA)
Occasionally still referred to as Zeolite or Zeolite mineral, ion exchange resin is

functionalized polymer/plastic beads that chemically react with ions in
water. It was developed as an alternative to zeolite and functions similarly.
2.4.2 Resin Properties
Nalcos LI-Series Water Softeners are supplied with a standard strong acid cation
(SAC) resin. This softening resin typically comes with the following properties:


2.4.3 Resin Operating Capacity
The capacity of standard strong acid cation (SAC) resin is dependent upon the
regenerant level of salt used during typical regeneration. The chart below shows
the average operating capacity in kilo-grains (kgr) per cubic foot (ft3) of resin on
the vertical axis compared to the regenerant level of salt used in pounds (lbs) per
cubic foot of resin (ft3):
Nalcos LI-Series water softeners come standard with a regenerant level setting
of approximately 10 pounds (lbs) per cubic foot of resin (ft3), which per the
above chart equates to approximately an estimated 28,500 grains per cubic
foot of softening resin.
The words approximately and estimated are used because the actual capacity
may differ from the calculated capacity do to many known and unknown variables
in the raw water. Industry standards and textbooks will therefore use a rounded
number of 30,000 grains as an average operating capacity per cubic foot of resin.


2.4.3 Resin Operating Capacity continued
This capacity is highly affected (up or down) by many factors, one of which is the
initial TDS loading of the influent water. There is a correction factor, which can
be used to estimate the operating capacity per the chart below:
For example, a raw water TDS level of 1000 would require a correction factor of
0.965 on the normal estimated capacity of 28,500 equating to an estimated =
27,500. The raw water TDS is one example of an operating parameter that can
severely affect the operating capacity of the ion exchange resin.


2.4.4 Resin Operating Parameters
Nalcos LI-Series Water Softeners are supplied with a standard strong acid cation
(SAC) resin. This softening resin typically comes with the following
recommended operating parameters:

Section 2: Technology Overview Siemens Water

Technologies
(USFilter)
2.4 Principles of Ion Exchange Resin C-211 Strong
Cation Resin
2.4.5 Resin Brand Equivalents
The following table shows typical resin brand equivalents:
Nalco LI-Series water softeners are supplied with Siemens branded strong acid
cation resin called C-211. The first group (circled group) is the typical
equivalent of Siemens Water technologies C-211 resin.
2.4.6 Resin Life Expectancy
Each application requires a different water quality. In general cation resin for
water softening and demineralization may last 5 to 10 years. Anion resins used in
demineralization last anywhere from 3 to 5 years and are dependent on
operational conditions.
Like every other resin, the life of mixed bed resin is dependent on the application
in which it is being used. Resin life is difficult to predict; in critical applications its
best to start analyzing and benchmarking the resin at least once per year.

2.5 The Filter Operating Sequence

The basic steps in the operation of a multi-media filter or activated carbon filter
are the filtration service cycle, backwash, media regeneration (if necessary), slow
rinse, and fast rinse.
2.5.1 Service
During the filtration service cycle in a multi-media filter, contaminants are

continually removed until the layers of media reach their maximum holding
capacity. This is usually measured by an increase in the pressure drop across
the filter. When the pressure drop increases approximately 5-10 psi greater than
a predetermined clean filter reading, the filter is backwashed to flush the
trapped particles from the media.
During the filtration service cycle in an activated carbon filter, chlorine is rapidly
removed while maintaining high flow rates through the filter bed. Organic
materials adsorption is generally slower. Over time, the carbon media can
become compacted or plugged with suspended solids.
The filter then needs to be backwashed. In general, activated carbon filters are
not backwashed as frequently as multi-media filters, which helps minimize
carbon breakage. The carbon will eventually be exhausted and need to be
replaced every several months to several years, depending on the type of
contaminants being removed.
2.5.2 Backwash
Once the pressure drop increases approximately 5-10 psi greater than a
predetermined clean filter reading, the filter unit needs to be backwashed. The
backwash cycle is to loosen the filter media since it has become compacted by
the weight of the water, and to remove any material that has been filtered out of
the water by the multi-media or activated carbon. The backwash consists of a
rapid upflow of water through the media layers. Particulates are flushed from the
bed as the media expands and the granules scour each other.
The backwash rate is normally 6 to 8 gpm/square foot of the filter media bed
area, and is programmed to last for approximately 14 minutes (see tables 2.5.7
System Specifications Multimedia Filters and 2.5.8 System Specifications
Activated Carbon Filters). The operator needs to apply enough backwash
water to expand the resin bed by about 50 percent.


2.5.2 Backwash continued
The backwash water flow rate is limited by and usually discharged to a box
(BACKWASH FLOW CONTROLLER) containing orifice plates or washers that
establish and measure the flow rate. Distributors at the top of the unit provide for
uniform water distribution and uniform wash-water collection. Underdrains help
the uniform distribution of the backwash water on the bottom of the resin.
2.5.3 Slow Settling Rinse

Next a slow downflow rinse helps the media to settle out after backwashing.
This step is typically programmed as estimated 4 minutes (see tables 2.5.7
System Specifications Multimedia Filters and 2.5.8 System Specifications
Activated Carbon Filters).
2.5.4 Fast Rinse

Finally, a fast downflow rinse steps helps restratify the layers and rinse the media
before the system returns to service. This step is typically programmed as
estimated 6 minutes (see tables 2.5.7 System Specifications Multimedia
Filters and 2.5.8 System Specifications Activated Carbon Filters).
2.5.5 Return to Service

After the fast rinse cycle, the regenerated tank will return to either service on
Simplex/Single tank systems and on multiple tank systems in parallel systems.
The multi-media filters have designed flowrates of 8 gpm/ft2 15 gpm/ft2 of

filtration media surface area (see tables 2.5.7 System Specifications
Multimedia Filters and 2.5.8 System Specifications Activated Carbon
Filters). This is recommended for influent suspended solid loads up to and
greater than 300 ppm. The lower the design flowrate (8 gpm/ft2), the better the
water quality with the lowest pressure loss.
The activated carbon filters have design flowrates of 1 gpm/ft2 4 gpm/ft2 of

filtration media surface area (see tables 2.5.7 System Specifications
Multimedia Filters and 2.5.8 System Specifications Activated Carbon
Filters). The design flowrate of 1 gpm/ft2 is for RO pretreatment to specifically
handle organics removal. The design flowrate of 2 gpm/ft2 is for RO pretreatment
applications to handle chlorine removal. The design flowrate of 4 gpm/ft2 is for
stand-alone filter applications to specifically handle chlorine removal.


2.5.6 General Design Parameters:
The following is a basic design guideline for filter applications and installations:
Feed Temperature 45 100OF
Feed Pressure 30 100 psig +/- 5 psig
Maximum Inlet Turbidity 30 NTU
Typical Sizing 10 gpm / ft2
Bed Depth 30 to 37 inches
Freeboard 65 to 100%
2.5.7 System Specifications Multimedia Filters:
2.5.8 System Specifications Activated Carbon Filters:
SEE APPENDIX IN BACK OF MANUAL FOR COMPLETE TECHNICAL SPECIFICATION OF THESE UNITS.

2.6 The Softener Operating Sequence

The basic steps in the operation of an ion-exchange softening unit are the
softening cycle, backwash, regeneration, slow rinse, and fast rinse.
2.6.1 Service
The softening service cycle involves the feeding of water into the unit until
hardness appears in the effluent from the unit. The cycle ends when 1 to 5 mg/l
of hardness is detected in the effluent. Almost all softening units have an alarm
on the water meter to indicate when a certain amount of water has passed
through the exchange unit. Loading rates for synthetic resins are in the area of
10 to 15 gpm/square foot of media surface area (see tables 2.6.7 2.6.10
System Specifications for Simplex, Duplex and Twin Softeners).
2.6.2 Backwash
Once the hardness breaks through, the softener unit needs to be regenerated. In
down-flow units the resin must first be backwashed to loosen the resin since it
becomes compacted by the weight of the water, and to remove any material that
has been filtered out of the water by the resin. The backwash rate is normally 6
to 8 gpm/square foot of zeolite bed area (see tables 2.6.7 2.6.10 System
Specifications for Simplex, Duplex and Twin Softeners). The operator needs
to apply enough backwash water to expand the resin bed by about 50 percent.
The backwash water is usually discharged to a box containing orifice plates that
establish and measure the flow rate.
Distributors at the top of the unit provide for uniform water distribution and
uniform wash-water collection. Underdrains help the uniform distribution of the
backwash water on the bottom of the resin.
2.6.3 Slow Rinse / Brine Eduction
To regenerate an ion-exchange unit, concentrated brine is educted into the unit

from the storage basin. The brine is diluted through the injector to a solution
containing about 10 percent salt before it is passed through the resin. The time
required for regeneration is about 20 to 35 minutes (see tables 2.6.7 2.6.10
System Specifications for Simplex, Duplex and Twin Softeners). The flow
rate of brine through the resin is measured in gallons per minute per cubic foot of
media.


2.6.3 Slow Rinse / Brine Eduction continued
The brine needs to be in contact with the resin long enough to allow for complete
exchange of the hardness ions in the resin with sodium ions in the brine. It is
better to allow too much time than to not allow enough. If the resin is not totally
recharged, the next softening run will be short.
2.6.4 Fast Rinse

The regeneration cycle must be followed by a rinse cycle to remove the
remaining brine from the tank. The total amount of rinse water needed is 20 to 35
gallons per cubic foot of resin (see tables 2.6.7 2.6.10 System Specifications
for Simplex, Duplex and Twin Softeners).
The total volume of the brine that is used during a regeneration cycle, together
with the rinse water that follows, varies from 1.5 to 7 percent of the amount of
water softened by the unit. The chloride concentration in this wastewater could
be as high as 35,000 to 45,000 mg/l.
2.6.5 Return to Service

After the Fast Rinse regeneration cycle, the regenerated tank will either return to
either service (on Simplex/Single tank systems and on multiple tank systems in
parallel systems) or will return to standby (on Duplex Alternating or Twin
systems).
2.6.6 General Design Parameters:

The following is a basic design guideline for softener applications and
installations:
Maximum Inlet Turbidity 5 NTU`
Sizing 2 gpm/ft2 minimum
Bed Depth 30 to 40, C-211 strong acid cation resin
Freeboard 53% to 125%
Capacities 30 Kgrains / ft3
Regeneration 15 lbs. NaCl / ft3


2.6.7 SIMPLEX Softener System Specification: All single models
SEE APPENDIX IN BACK OF MANUAL FOR COMPLETE TECHNICAL

SPECIFICATION OF THIS UNIT.


2.6.8 DUPLEX Softener System Specification: 1 & 1.5 Valves
SEE APPENDIX IN BACK OF MANUAL FOR COMPLETE TECHNICAL SPECIFICATION OF THIS UNIT.
2.6.9 DUPLEX Softener System Specification: 2 & 3 Valves


2.6.10 TWIN Softener System Specification: all twin models


3.1 STEP 1 Equipment Design Check-List
IT IS HIGHLY RECOMMENDED TO KEEP THIS PAGE AS A MASTER COPY
AND MAKE A XEROX COPY TO FILL IN FOR EACH LI-SERIES SYSTEM.
The following items should be validated with the customer via the Nalco Sales
Representative prior to arrival for the installation:
ITEM & DESCRIPTION RANGE ACTUAL
3.1.1 Water Source: City / Well ________
3.1.2 Water Source Line Pressure 30-100psi ________
3.1.3 Water Source Temperature 45F 100F ________
3.1.4 Backwash Water Drain Available & Sufficient? ________
3.1.5 Electrical Supply 120VAC/Single Phase ________
3.1.6 Manual Isolation Valves Inlet, Outlet, Bypass ________
It is critical to validate the items one final time in an effort to avoid wasting a trip to
the customers location. The following explains the range of operation:
3.1.1 Water Source

The water source is typically either municipal city water source, or local well water
source. The municipal city source is typically either treated surface water, i.e. Lake
Michigan water at Nalco Naperville, or the municipal city source is from deep wells.
The water will typically have a higher hardness level from the local well or from the
municipal deep well water source.
Before starting installation, please check with the customer to confirm the water
source. If the water source is other than a city municipal supply or local well,
please contact the Nalco Sales Representative and NGES Tech Support at 630-
848-3387 before proceeding to confirm non-standard softening and/or filtration
equipment was provided. In addition, check the hardness level and TDS of the
incoming water. If the TDS is greater than 750ppm as CaCO3, and/or if the
Turbidity is 5 or greater, please contact the Nalco Sales Representative and NGES
Tech Support at 630-848-3387 before proceeding to confirm non-standard
softening and/or filtration equipment was provided.
3.1.2 Water Source Line Pressure

The control valve needs a minimum water source line pressure of 30 psi and a
maximum of 100psi to operate effectively. Optimal water source line pressure is 60
psi - 80 psi. Systems with 16 diameter resin tank or larger require a minimum of
40 psi.


3.1.2 Water Source Line Pressure continued
Pressures <30 psi (<40 psi for 16 diameter or larger) will reduce backwash flow
rates and not provide for a effective softener or filter backwash. In addition,
particulate and bacteria can build up in the softener resin bed or filter media bed.
A bed replacement will be required in as little as a few weeks. Pressures <30 psi
( <40psi for 16 diameter or larger) will require a booster pump.
Pressures >100 psi will increase backwash flow rates and result in the potential
loss of the top layer of filter media or softening resin. Loss of this layer of filter
media dramatically reduces filtration efficiency, loss of this layer of softening resin
will dramatically reduce the resin bed capacity. Additional media or resin will have
to be added to the filter to restore performance. Pressures >100 psi may also
damage the flow control valve. Pressures >100 psi will require a pressure
regulator to reduce pressure below 100 psi.
Before starting installation, please check with the customer to confirm the system
water source line pressure. If the system water source line pressure is <30 psi
(<40 psi for 16 diameter or larger) or >100 psi, please contact the Nalco Sales
Representative and NGES Tech Support at 630-848-3387 immediately before
proceeding to confirm the need for a booster pump or pressure regulator has been
addressed.
3.1.3 System Water Temperature
System water temperature must be between 45-100F. Temperatures <45F or

>100F will require non-standard equipment containing special materials of
construction. Before starting installation, please check with the customer to
confirm the temperature. If the system water temperature is <40F or >105F,
please contact the Nalco Sales Representative and NGES Tech Support at 630-
848-3387 immediately before proceeding to confirm non-standard equipment has
been provided.


3.1.4 Backwash Water Drain
A drain sized to accommodate the backwash flow MUST be in the vicinity of

the filter. Before starting installation, please check with the customer to confirm
the location of the backwash drain line. Look to see if backwash drain line from the
softener or filter system has to go across an area designated for equipment or foot
traffic. If it does, please contact the Nalco Sales Representative and NGES Tech
Support at 630-848-3387 immediately before proceeding to confirm the drain line
conflict will need to be addressed.
3.1.5 Electrical Supply
An uninterrupted 120V alternating current (AC) electrical supply is required.

Make sure the supply is always on, and cannot be turned off with another
switch. Before starting installation, please check with the customer to confirm the
location and uninterrupted supply. Please contact the Nalco Sales Representative
and NGES Tech Support at 630-848-3387 immediately before proceeding to
confirm if the electrical supply is local to the location of the system, uninterrupted,
and switch always on of the unit purchased and to be installed.
3.1.6 Manual Isolation Valves
Always install manual inlet, outlet, and bypass valves on the system for
preventative maintenance servicing, troubleshooting, and general system
monitoring. Before starting installation, please check with the customer to confirm
the location and uninterrupted supply. Please contact the Nalco Sales
Representative and NGES Tech Support at 630-848-3387 immediately before
proceeding to confirm if the electrical supply is local to the location of the system,
uninterrupted, and switch always on of the unit purchased and to be installed.

3.2 STEP 2 PRE-INSTALLATION CHECK-LIST

NOTE: Initial Start-Up must be performed by Authorized Factory Technician
such as trained Nalco Services personnel - otherwise the Equipment
Guarantee/Warrantee will be Null and Void.
If the filter is already installed and operating upon your arrival, contact the
Nalco Sales Representative or NGES at 630-848-3387 before proceeding.
Customer: ____________________________________ _____ _____ ______________
Address: _______________________________________________________________
Contact: ___________________________________ Tel: _______________________

FAX COMPLETED TO: 630-305-1800
Start-Up Date: ______________________________ Fax: _______________________
ATTN: NGES HELP DESK

Softener / Filter Data:
Nalco SAP Sales Order #: ___________ Nalco SAP Part #: ___________________
Vendor Part #: _____________________ Tank Diameter: _____________________
Single/Twin/Duplex: _________________________ If Duplex: Alternating / Parallel
Control Valve - Inlet / Outlet Diam: _____________ Drain Diam: _____________
Media Quantity: __________FT3 Media Type: Resin / Multi-media / Activated Carbon
Plant Connection Data:
Electrical: Control Power: ______VAC / ____ Phase Water Source: CITY / WELL
Water Source Line Pressure __________PSI Water Source Temp: ______F
Backwash Drain Distance: __________FT Backwash Drain Size: _____
Manual Isolation Valves on INLET: _Y / N_ OUTLET: _Y / N_ DRAIN: _Y / N_

Section 3:
Installation and Start-Up
STEP 3 UNPACKING
SOFTENERS
& FILTERS


3.3 STEP 3 UNPACKING
3.3.1 Unpacking Checklists
LI-Series softener and filter components may be attached to sides of crate or

packed in boxes within shipping crate. Be sure to remove all components before
disposing of crate.
Do not lift or pull fiberglass vessels by side ports; internal components may be
damaged. Vessels shipped with media installed should not be tipped beyond a 45-
degree angle.
a. Inspect shipping crate(s) and packages for damage.
NOTE: Before signing bill of lading report any damage to NGES Tech
Support at 630-848-3387 immediately.
b. Remove top of crate then break down sides as necessary to remove

contents.
NOTE: Report any damage to NGES Tech Support at 630-848-3387

immediately.
c. Unpack LI-Series system as close as possible to installation location.
d. Media, Control Valves, gaskets, bolts, are contained in cardboard boxes

packed in crate(s).
e. Most importantly, before any installation or

assembly is done, take a physical inventory of all
components contained in the boxes per the
various system UNPACKING CHECKLISTS on the
following pages.


3.3.1.1 Unpacking Checklist: TWIN Softener Systems
NOTE: You will need to take a physical inventory of the items before
proceeding with installation. If any of the items listed below are not present,
contact NGES Tech Support immediately at 630-848-3387 before proceeding.
Each TWIN SOFTENER assembly consists of the following below:
1. (2) Fiberglass vessels with PVC riser tube distributor*
2A. (1) Tank 1 Control Valve Kit, including
- (1) Control valve with cover*
- (1) Tank-Valve bushing (1 valves only)*
- (1) Upper disperser (installed on 1 valve)*
2B. (1) Tank 2 Adapter Kit, including*
- (1) Tank Adapter*
- (1) Tank-Valve bushing (1 valves only)*
- (1) Interconnecting piping assembly*
- (1) Lot of couplings and clips or fasteners*
3. (1) Tank-Valve bushing (1 valves only)
4. (1) Drain line flow control (DLFC) housing
5. (1) Tube fitting for brine inlet line
6. (1) Kit with assorted DLFC/injector parts
7. (2) Upper disperser (installed on 1 valve)
8. (1) Lot Cation Resin and gravel if necessary*
9. (1) Water meter (installed on 1 valve)*
10. (2) Operating Manuals*
11. (1) Hardness test kit
---- (1) Length copper tubing w/ clips for inlet*
Figure 3.3.1.1A: TWIN Softener Components

* Items with asterisk NOT shown in photo


3.3.1.1 Unpacking Checklist: TWIN Softener Systems
Each BRINE TANK assembly consists of the following components below.
12. (1) Brine tank with cover
13. (1) Well with cap
14. (1) Salt Grid
15. (1) Overflow fitting
16. (1) Safety Valve / Brine Float Valve
17. (1) Air check assembly (for 24 brine tanks)
18. (1) 3/8 tube elbow, fittings (for 7 16 systems)*
19. (1) 0.5 bushing, elbow, fittings (for 18 24 systems)
20. (1) length 18 tubing with tee (for 14 24 systems)*
21. (1) Grommet for brine line hole in tank*
Figure 3.2.1.1B: TWIN Softener BRINE TANK Components



3.3.1.2 Unpacking Checklist: SIMPLEX Softener Systems
Each SIMPLEX SOFTENER consists of the following components below.

1. (1) Fiberglass vessel with PVC riser tube distributor*
2. (1) Control Valve with cover*
3. (1) Tank-Valve bushing (for 16-24 tanks with 1 valves)*
7. (1) Upper Disperser (1.5 valves only)
9. (1) Bushing (3 valves only)*
Figure 3.3.1.2A: SIMPLEX Softener Components



3.3.1.2 Unpacking Checklist: SIMPLEX Softener Systems

14. (1) Salt Grid (for 24 30 tanks)
16. (1) Safety Valve / Brine Float Valve (for 18 and 24
22. (1) Lot x 1/8 gravel (39 50 brine tanks)*
Figure 3.2.1.2B: SIMPLEX Softener BRINE TANK Components



3.3.1.3 Unpacking Checklist: DUPLEX Softener Systems

Each DUPLEX SOFTENER consists of the following components below.

1. (2) Fiberglass vessel with PVC riser tube distributor*
3A. (2) Tank-Valve bushing (for 16-24 tanks with 1 valves)*
3B. (2) 1 x FPT bushing (3 valves only)
7. (2) Upper Disperser (1.5, 2, 3 valves only)
9. (2) Bushing (3 valves only)*
---- (2) Flange connector (3 valve only)*
---- (2) Brine line flow control housing (3 valve only)*
Figure 3.3.1.3A: DUPLEX Softener Components





14. (1) Salt Grid
16. (1) Safety Valve / Brine Float Valve
---- (1) Lot x 1/8 gravel (for 39 and larger brine tanks)
Figure 3.2.1.3B: DUPLEX Softener BRINE TANK Components




Each DUPLEX SYSTEM consists of the following ALTERNATING KIT:
22. (1) 25 RJ45 phone cable*

23. (1) 25 3-wire meter cable*
24. (1) cable fitting with lock nut
25. (1) remote meter with bracket and tester*
26. (4) end connectors for actuated valves*
27. (2) NO valves w/mounted & tubed 24VAC solenoid valve
28. (1) Union Tee*
29. (1) 20 tubing*
Figure 3.3.1.3C: (1) cable Figure 3.3.1.3D: Normally

fitting with lock nut Open Diaphragm Valve
w/ mounted 24VAC
Solenoid (1 of 2 shown)


3.3.1.4 Unpacking Checklist: MULTI-MEDIA Depth Filter
& ACTIVATED CARBON Filter Systems

Each MMF or AC FILTER system consists of the following components:
1. (1) Fiberglass vessel with PVC riser tube distributor assembly*

3. (1) Tank-Valve bushing (for 16-18 tanks with 1 valves)*
5. (1) Drain line bushing (for 1.5 valves w/ DLFC>25)*
6. (1) Kit with assorted DLFC washers
7. (1) Upper Disperser (1.5 and 2 valves only)
8. (1) Lot Carbon or Multi-media and gravel if necessary*
Figure 3.2.1.4A: MULTI-MEDIA or ACTIVATED CARBON FILTER system
Items with asterisk NOT shown in photo

Section 3:
STEP 4 LOCATING
SOFTENERS
& FILTERS


3.4 STEP 4 LOCATING
3.4.1 Locating Softener / Filter System
a. Pallets should be lifted by a forklift or crane. LI-Series systems should

be rigged from the bottom. Do not allow rigging straps to contact
system components.
NOTE: Report any damage to NGES Tech Support at 630-848-3387

immediately.
b. LI-Series system should be located on a level floor or housekeeping

pad.
c. Vibration pads (not included) may be used under components and pipe
stands for vibration isolation. Vibration pads, if used, should be placed
under all components to ensure proper alignment.
d. Floor load rating must be sufficient to accept LI-Series System weight.
NOTE: Contact NGES Tech Support at 630-848-3387 for

confirmation on weight information.
e. Place system in close proximity to water to be filtered. Place tanks so

that ample room around control valves is available for servicing, as
well as sufficient space behind the valve(s) is available for piping.
NOTE: If the filter will be over 20 feet from water source, contact
NGES Tech Support at 630-848-3387.
f. Protect system from water temperatures below 45F and above 100F
unless filter is designed for those temperature applications.
NOTE: See section 3.1.3 System Water Temperature for additional

explanation and instructions.
o WARNING!!! TIPPING HAZARD may exist on empty free-standing

single or multi-vessel systems
o WARNING!!! Be sure that vessels are properly placed and aligned

before adding base media. With media added, vessels will be
very difficult to move.
o WARNING!!! Do not add stone base media to systems piped in

PVC at this time. Damage to lower distributor may result.

Section 3:
STEP 5 VALVE & PIPING

INSTALLATION
TWIN SOFTENER

3.5 STEP 5 VALVE & PIPING INSTALLATION

3.5.1 TWIN SOFTENER Valve and Piping Installation
Figure 3.5.1.1A: Piping Arrangement for TWIN SOFTENER
Use a silicone base grease to lubricate the two (2) O-rings at the base of the
control valve. Also lubricate the two (2) O-rings at the base of the tank #2
adapter.
Units with 1 valves only: Install the supplied upper disperser to the bottom
of the control valve and tank #2 adapter by pushing the large end of the disperser
into the groove on the bottom of the valve until the disperser locks in place.
16 diameter tank systems with 1 valves: Thread the supplied tank-to-valve

bushing into each vessels top opening
Carefully thread the control valve and the adapter clockwise into the center
opening in the top of each tank. On 1 valves, first install the supplied tank-to
valve bushing. Make sure that the riser pipe goes into the center opening in the
base of the valve or adapter. Hand-tighten only - do not use a wrench or any
device to apply additional torque or leverage.


3.5.1 TWIN SOFTENER Valve and Piping Installation
Connect the control valve (on tank #1) to the adapter (on tank #2). For 1 valves,
lubricate the four (4) o-ring couplings (Figure 1), insert them into both ends of the
interconnecting piping yoke, and use the four (4) clips to attach the yoke to the
valve and adapter. For 1 valves, lubricate the four (4) o-rings on the ends of
the interconnecting piping yoke, plug the yoke into the valve and adapter, and
secure with the eight (8) fasteners.
WARNING!!! Do NOT plug in the power cord at this time.
Locate the brine tank between the two softeners. The brine tank location should
be such that it will not interfere with access to the softener control valve or filling
the brine tank with salt. The brine tank must be placed on a smooth firm
foundation.
Install the piping using the following procedures and the applicable installation
drawing on the next page. Comply with all local, state, and federal plumbing
codes.
Install the water meter using the applicable installation drawing and the meter
drawing in the Control Valve Manual vendor literature.
On units with meters, clip one side of the meter to the valves inlet and
outlet connections and the other side to the supplied 1 FNPT threaded pipe
yoke, making sure that the arrows on the meter point toward the valve inlet.
On units with 1 meters, clip the side of the meter with the o-rings and
couplings to the valves inlet and outlet connections. On units with 1 meters,
thread the male end of the meter into the valves outlet.
NOTE: Make sure the meter is installed with its dome on top (face up).
Connect the inlet and outlet piping to the valve and/or meter; include unions
for easy servicing.
Figure 3.5.3.1B: 1 Valve Figure 3.5.3.1C: 1.5 Valve


3.5.1 TWIN SOFTENER Valve and Piping Installation continued
Connect the open port of the DLFC housing (the larger connection on the side of
the valve) to an open floor drain.
There must be a 4 air gap between the drainpipe and the floor drain. Do not
reduce the pipe or tube size of the drain port connection. Make as short a run of
drain piping as possible. If it is necessary to run the drain line overhead, consult
Technical Support for proper recommendations.
Loosely thread the supplied tubing fitting onto the valves brine inlet connection.
Run the brine tubing between the air check valve on the brine tank to the control
valves brine inlet connection. Cut any excess tubing. Refer to Figure 3.5.1.1A:
Piping Arrangement for TWIN SOFTENER.
The manufacturer recommends that drain tubing be installed connecting the
overflow elbow on the side of the brine tank to an open floor drain. Do not run
this line overhead; it must be to a gravity drain. Do not make a direct connection
to the floor drain.
Open the bypass valve, close the inlet and outlet valves, and slowly turn on the
main water supply. Open a cold soft water tap nearby and let it run a few minutes
or until the system is free from foreign material that may have resulted from the
installation. Once clean, close the water tap and bypass valve, and open the inlet
valve (leave outlet shut).
Plug the loose end of the meter cable into the meter cap assembly (the other end
is attached to the control drive).
Plug the control unit into an outlet that can deliver the proper type of electrical
power.


3.5.2 TWIN SOFTENER Injector Components and Assembly
Verify the correct injector assembly is used using the following procedure and
referring to Figure 3.5.1.1A : Piping Arrangement for TWIN SOFTENER
above. Each control valve has been configured for use with a specific diameter
tank. If a smaller or larger tank is used instead, a different injector will need to be
used:
Figure 3.5.2.1A: Injector Components and Assemblies

Remove the mounting bolts and lift off the cover and gasket.
Compare the installed injector nozzle and throat to the specification table
in section 2.6.7 2.6.10 System Specifications for Simplex, Duplex and
Twin Softeners). If the correct color injector is already installed, skip to
step 6.
Using a standard screwdriver, unscrew the installed injector nozzle from
the injector body.
Unscrew the installed injector throat from the injector body.
Install the required injector throat and nozzle (per section 2.6.7 2.6.10
System Specifications for Simplex, Duplex and Twin Softeners)
these are included in the supplied kit (see Figure 3.5.2.1A: Injector
Components and Assemblies). Screw them into the injector body until
snug, but do not over tighten.
Reinstall the injector gasket, cover, and bolts.

3.5.3 TWIN SOFTENER Drain Line Flow Controller (DLFC)

Note the required Backwash / Rapid Rinse flow DLFC in section 2.6.7 2.6.10
System Specifications for Simplex, Duplex and Twin Softeners). Out of the
bag of in line flow control (DLFC) washers, choose the one with this flow
stamped on it (flows are in hundredths of a GPM; i.e. 500 = 5 GPM). Install this
DLFC flow washer onto the inlet side of the supplied DLFC housing, as shown in
Figure 3.5.3.1A: DLFC Washer Installation below. Make sure the numbers on
the washer are facing out.
Install the DLFC housing. On 1 valves, the housing is the uppermost part of the
valve. On 1.5 valves, the housing is shipped loose, and should be installed onto
the control valve s drain connection, which is on the left as the valve is viewed
from the front. Make sure that the arrow on the housing is pointing away from the
valve.
Figure 3.5.3.1A: DLFC Washer Installation

Section 3:

INSTALLATION
SIMPLEX (SINGLE)
SOFTENERS


3.5.4 SIMPLEX SOFTENER Valve and Piping Installation
Figure 3.5.4.1A: Piping Arrangement for TWIN SOFTENER
Use a silicone base grease to lubricate the two (2) O-rings at the base of each
control valve.
Install the valves upper disperser to the bottom of the valve using its instruction
sheet (both supplied with the valve). Carefully thread the control valve clockwise
into the center opening in the top of the tank.


3.5.4 SIMPLEX SOFTENER Valve and Piping Installation cont
Make sure that the riser pipe goes into the center opening in the base of the
control valve. Hand tighten only - do not use a wrench or any device to gain
leverage or apply additional torque. On the 3 valve, line up the boltholes on the
tank adapter or flange ring with the tapped holes on the softener vessel, and bolt
in place.
Locate the brine tank near the softener. The brine tank location should be such
that it will not interfere with access to the softener control valve or filling the brine
tank with salt. The brine tank must be placed on a smooth firm foundation.
For 39 and larger brine tanks only: On the outside of the brine well, pour in the
proper quantity of x 1/8 gravel (see section 2.6.7 2.6.10 System
Specifications for Simplex, Duplex and Twin Softeners), and level it.
Install the piping according to Figure 3.5.4.1A: Piping Arrangement for TWIN
SOFTENER. The manufacturer recommends installing a manual bypass line
connecting the common inlet and outlet lines so that the softener system can be
bypassed if not in use.
CAUTION Solder joints at the drain must be done prior to connecting the
drain line to the valve. Failure to do this could cause interior damage to the
drain line flow control (DLFC).
Connect the open port of the DLFC housing to an open floor drain. Do not reduce
the pipe or tube size of the drain port connection. Make as short a run of drain
piping as possible. If it is necessary to run the drain line overhead, consult
technical support for recommendations.
Loosely thread the supplied tubing fitting onto each valves brine inlet connection.
3 valves only: Install the supplied bushing to the 1 brine inlet connection.
Cut the supplied brine tubing into a 6 piece. Run one piece between the air
check assembly on the brine tank to the valves brine inlet connection.

to the floor drain.


3.5.5 SIMPLEX SOFTENER Injector Components and Assembly
referring to Figure 3.5.5.1A : Piping Arrangement for SIMPLEX SOFTENER
above. Each control valve has been configured for use with a specific diameter
tank. If a smaller or larger tank is used instead, a different injector will need to be
used:

step 6.
the injector body.


3.5.6 SIMPLEX SOFTENER Drain Line Flow Controller (DLFC)
Units with 1, 1.5, or 2 valves:
o Note the required Backwash / Rapid Rinse flow DLFC in Table 1-1. Out of
the bag of in line flow control (DLFC) washers, choose the one with this
flow stamped on it (flows are in hundredths of a GPM; i.e. 500 = 5 GPM).
Install this DLFC flow washer onto the inlet side of the supplied DLFC
housing, as shown in Figure 3.5.6.1A-Valve DLFC Washer Installation.
Make sure the numbers on the washer are facing out.
Figure 3.5.6.1A - 1, 1.5, and 2 Valve DLFC Washer Installation
Units with 3 valves:

Reference Figure 3.5.6.1B - 3 Valve DLFC Washer Installation on the
next page and configure the DLFC housing using the following procedures:
o Loosen and remove the six bolts connecting the two portions of the DLFC
housing (shipped loose with the valve). Lift off the upper portion and the
flat disc beneath it - containing four cutouts. In an effort to simplify the
drawing, the flat disc is shown with all four cutouts punched out and only
one washer.
o Using the washers included in the supplied sizing kit, set up the valve for
the DLFC flow listed in section 2.6.7 2.6.10 System Specifications for
Simplex, Duplex and Twin Softeners. Combine the different washers so
they add up to the necessary flow (e.g., 70 GPM would be (2) 25 GPM
washers & (1) 20 GPM washer).


3.5.6 SIMPLEX SOFTENER Drain Line Flow Controller (DLFC)
o Each washer is labeled with the flow it is sized for. Make sure the
numbers on the washers are facing down, and punch out the same
number of holes in the disk, as there are washers.
o Replace the flat disc, making sure to position the holes in the disc directly
above the washers. Reinstall the top portion of the DLFC housing, and
replace the six bolts.
o Thread the DLFC housing onto the valves drain connection. This is the
smaller connection on the right side of the 2 valve or on top of the 3
valve, as observed from the front (where the controller is mounted). Make
sure that the arrow on the housing is pointing away from the valve.
Figure 3.5.6.1B - 3 Valve DLFC Washer Installation

Section 3:

INSTALLATION
1.0 & 1.5

DUPLEX SOFTENERS


3.5.7 DUPLEX 1.0 & 1.5 SOFTENER Valve and Piping Install
Figure 3.5.7.1A: Piping Arrangement for 1 & 1.5 DUPLEX SOFTENER
control valve.
Units with 1 valves only: Install the supplied upper disperser to the bottom
of each valve by pushing the large end of the disperser into the groove on the
bottom of the valve until the disperser locks in place.


16 diameter tank systems with 1 valves: Thread the supplied tank-to-valve
bushing into each vessels top opening
Carefully thread each control valve into the opening in the top of the tank (or
bushing if applicable). Make sure that the riser tube distributor assembly goes
into the center opening in the base of the control valve. Hand tighten only do
not use a wrench or any device to apply additional torque.
WARNING!!! Do NOT plug in the power cord at this time.
not interfere with access to the softener control valve or filling the brine tank with
salt. The brine tank must be placed on a smooth firm foundation.
Install the piping according to the System 7 Duplex Alternating Installation with
Remote Meter, Figure 3.5.7.1A: Piping Arrangement for 1 & 1.5 DUPLEX
SOFTENER. The brine draw lines from both control valves must be run to the
common brine tank. Components supplied by the manufacturer are the 3-way
solenoid valves and the Normally Open Diaphragm valves. Follow all Installation
Instructions in Model 2750 or 2850 Control Valve Service Manuals (Appendices)
Loosely thread the supplied tubing fitting onto each valves brine inlet connection.
Cut the supplied brine tubing into (3) 6 pieces. Run one piece between the air
check assembly on the brine tank to the supplied tubing tee and the other two
pieces between the tee and each valves brine inlet connection. Refer to Figure
3.5.7.1B: Brine Tubing Connection below:
Figure 3.5.7.1B: Brine Tubing Connection



to the floor drain.
NOTE: Install the remote meter in a horizontal portion on the OUTLET

common soft water line.
NOTE: Make sure the arrow on the meters brass casting is pointing in the
proper direction (same as flow).
NOTE: For ease of service, a union should be installed on the meter outlet
(the inlet has a built-in union).
3200NT CONTROLLER INSTALLATION
A. Transformer Wiring
Refer to the 3200NT Timer Service Manual Transformer Installation and
2750/2850/3150 Timer Wiring Diagram. These can be found in the 3200NT
manual Table of Contents.
The 3200NT Timer is supplied with a 120VAC to 24VAC transformer that

requires wiring into the 3200NT PCB. The transformer is wired into P1 of the
3200NT PCB, and grounded on the chassis of the 3200NT assembly.
B. Solenoid Valve Wiring

Refer to the 3200NT Timer Service Manual 2750/2850/3150 Timer Wiring
Diagram. A 3-Way Universal 24VAC solenoid valve is supplied for control of the
effluent product valve that is utilized in the system. The solenoid valve is wired
into the 3200NT Timer PCB at terminal P6.
C. Solenoid Valve Piping

The supplied Asco 24VAC Universal Solenoid valve is pre-mounted and tubed to
the diaphragm valve. The valve utilizes line pressure to open and close the valve.
No further assembly is required after it is wired to the 3200NT PCB.


D. Duplex, Triplex, and Quadplex Network Configuration Wiring

The standard systems are duplex alternating systems. They can be expanded in
the future to be triplex or quadplex operating. The 3200NT Timer has the
capability to be wired and programmed to operate as a duplex, triplex, or
quadplex system via a 6-place, 4-conductor RJ5 telephone cable.
NOTE: Refer to the 3200NT Timer Service manual Network Timer System
Configuration Wiring Diagrams for the RJ5 cable termination schematics.
Contact NGES Tech Support at 630-848-3387 with any questions.
E. Duplex, Triplex, and Quadplex Network Programming

o Refer to the 3200NT Timer Service Manual Master Programming Mode
Flow Chart (yellow supplement sheets) for programming instructions for
the 3200NT. In addition, refer to the Equipment Specification table in
section 2.6.7 2.6.10 System Specifications for Simplex, Duplex and
Twin Softeners of this manual for the programming parameters specific
to your softener.
o The system utilizes the System 7 programming system type.
o Cycle Steps are utilized during operation of the 3200NT controlled duplex
softeners. The exact values are located in section 2.6.7 2.6.10 System
Specifications for Simplex, Duplex and Twin Softeners of this manual.
a. Cycle Step 1 = Backwash

b. Cycle Step 2 = Brine In + Slow Rinse
c. Cycle Step 3 = Fast Rinse
d. Cycle Step 4 = Brine Fill
NOTE: Refer to the 3200NT Timer Service Manual Troubleshooting

section for information on any communication or programming problems.
NOTE: For Duplex (or Triplex and Quadplex) applications, the Lag unit
must be programmed prior to the Lead unit programming. Feed water
hardness values are programmed in the Lead valve, as the water meter is
connected to this valve. Contact NGES Tech Support at 630-848-3387 with
any questions.


3.5.8 DUPLEX 1.0 & 1.5 SOFTENER Injector Components
referring to Figure 3.5.7.1A : Piping Arrangement for 1.0 & 1.5 DUPLEX
SOFTENER above. Each control valve has been configured for use with a
specific diameter tank. If a smaller or larger tank is used instead, a different
injector will need to be used:

step 6.
the injector body.


3.5.9 DUPLEX 1.0 & 1.5 SOFTENER Drain Line Flow Controller
Units with 1, 1.5, or 2 valves:
o Install this DLFC flow washer onto the inlet side of the supplied DLFC
housing, as shown in Figure 3.5.9.1A - DLFC Washer Installation. Make
sure the numbers on the washer are facing out.
Figure 3.5.9.1A - 1, 1.5, and 2 Valve DLFC Washer Installation

Section 3:

INSTALLATION
2.0 & 3.0

DUPLEX SOFTENERS


Figure 3.5.10.1A: Piping Arrangement for 2 & 3 DUPLEX SOFTENER


control valve.
Install each valves upper disperser to the bottom of the valve using its instruction
sheet (both supplied with the valve). Carefully thread the control valve clockwise
into the center opening in the top of the tank.
leverage or apply additional torque. On the 3 valve, line up the bolt holes on the
tank adapter or flange ring with the tapped holes on the softener vessel, and bolt
in place.
be such that it will not interfere with access to the softener control valve or filling
the brine tank with salt. The brine tank must be placed on a smooth firm
foundation.
For 39 and larger brine tanks only: On the outside of the brine well, pour in the
proper quantity of x 1/8 gravel (see section 2.6.7 2.6.10 System
Specifications for Simplex, Duplex and Twin Softeners ), and level it.
Install the piping according to the System 7 Duplex Alternating Installation with
Remote Meter, Figure 3.5.10.1A: Piping Arrangement for 2 & 3 DUPLEX
SOFTENER.
Connect the inlet and outlet piping; include unions for easy servicing. The inlet
valve connects to the rear of the control valve. The outlet valve is on the right
side of the valve as you face the controller.
drain line flow control (DLFC) washer.
Connect the open port of the DLFC to an open floor drain. Do not reduce the pipe
or tube size of the drain port connection. Make as short a run of drain piping as
possible. If it is necessary to run the drain line overhead, consult the factory for
proper recommendations.
3 Valves only: Install the supplied Brine Line Flow Control (BLFC), 1 PVC
female adapter, 1 x PVC bushing, and elbow tubing adapter to the 1
brine connection on the control valve.


Cut the supplied 18 piece of tubing into three 6 pieces. Run one piece between
the air check assembly on the brine tank and the supplied tubing tee, and run the
other two pieces between the tee and each valves brine inlet connection. Refer
to Figure 3.5.7.1B: Brine Tubing Connection below:
Figure 3.5.10.1B: Brine Tubing Connection

The manufacturer recommends that drain tubing (not supplied) be installed
connecting the overflow elbow on the side of the brine tank to an open floor
drain. Do not run this line overhead; it must be to a gravity drain. Do not make a
direct connection to the floor drain.
Place approximately 12" of water in the brine tank. Do not add salt to the brine
tank at this time.
main water supply. Open a cold soft water tap nearby and let it run a few minutes
or until the system is free from foreign material that may have resulted from the
installation. Once clean, close the water tap and bypass valve, and open the inlet
valve (leave outlet shut).
NOTE: Install the remote meter in a horizontal portion on the OUTLET
common soft water line.
NOTE: Make sure the arrow on the meters brass casting is pointing in the
proper direction (same as flow).
NOTE: For ease of service, a union should be installed on the meter outlet
(the inlet has a built-in union).


3200NT CONTROLLER WIRING
A. Transformer Wiring
Refer to the 3200NT Timer Service Manual Transformer Installation and
2900/3900 Timer Wiring Diagram. These can be found in the 3200NT manual
Table of Contents.
The 3200NT Timer is supplied with a 120VAC to 24VAC transformer that

requires wiring into the 3200NT PCB. The transformer is wired into P1 of the
3200NT PCB, and grounded on the chassis of the 3200NT assembly.
B. Duplex, Triplex, and Quadplex Network Configuration Wiring

The standard systems are duplex alternating systems. They can be expanded in
the future to be triplex or quadplex operating. The 3200NT Timer has the
capability to be wired and programmed to operate as a duplex, triplex, or
quadplex system via a 6-place, 4-conductor RJ5 telephone cable.
NOTE: Refer to the 3200NT Timer Service manual Network Timer System
Configuration Wiring Diagrams for the RJ5 cable termination schematics.
C. Duplex, Triplex, and Quadplex Network Programming

o Refer to the 3200NT Timer Service Manual Master Programming Mode
Flow Chart (yellow supplement sheets) for programming instructions for
the 3200NT. In addition, refer to the Equipment Specification table in
section 2.6.7 2.6.10 System Specifications for Simplex, Duplex and
Twin Softeners of this manual for the programming parameters specific
to your softener.
o The system utilizes the System 7 programming system type.
o Cycle Steps are utilized during operation of the 3200NT controlled duplex
softeners. The exact values are located in section 2.6.7 2.6.10 System
Specifications for Simplex, Duplex and Twin Softeners of this manual.
a. Cycle Step 1 = Backwash

b. Cycle Step 2 = Brine In + Slow Rinse
c. Cycle Step 3 = Fast Rinse
d. Cycle Step 4 = Brine Fill

NOTE: Refer to the 3200NT Timer Service Manual Troubleshooting

section for information on any communication or programming problems.
NOTE: For Duplex (or Triplex and Quadplex) applications, the Lag unit
must be programmed prior to the Lead unit programming. Feed water
hardness values are programmed in the Lead valve, as the water meter is
connected to this valve. Contact NGES Tech Support at 630-848-3387 with
any questions.
3.5.11 2.0 & 3.0 DUPLEX SOFTENER Injector Components
referring to Figure 3.5.10.1A : Piping Arrangement for 2.0 & 3.0 DUPLEX
SOFTENER above. Each control valve has been configured for use with a
specific diameter tank. If a smaller or larger tank is used instead, a different
injector will need to be used:


3.5.11 2.0 & 3.0 DUPLEX SOFTENER Injector Components
step 6.
the injector body.
snug, but do not overtighten.
3.5.12 2.0 & 3.0 DUPLEX SOFTENER Drain Line Flow Controller

housing, as shown in Figure 2-5. Make sure the numbers on the washer
are facing out.
Figure 3.5.12.1A - 2 Valve DLFC Washer Installation

3.5.12 2.0 & 3.0 DUPLEX SOFTENER Drain Line Flow Controller

Reference Figure 3.5.6.1B - 3 Valve DLFC Washer Installation on the
next page and configure the DLFC housing using the following procedures:
flat disc beneath it - containing four cut-outs. In an effort to simplify the
drawing, the flat disc is shown with all four cut-outs punched out and only
one washer.
the DLFC flow listed in section 2.6.7 2.6.10 System Specifications for
Simplex, Duplex and Twin Softeners. Combine the different washers so
they add up to the necessary flow (e.g., 70 GPM would be (2) 25 GPM
washers & (1) 20 GPM washer).
o Each washer is labeled with the flow it is sized for. Make sure the
numbers on the washers are facing down, and punch out the same
number of holes in the disk, as there are washers.
smaller connection on the right side of the 2 valve or on top of the 3
valve, as observed from the front (where the controller is mounted). Make
sure that the arrow on the housing is pointing away from the valve.
drawing, the flat disc is shown with all four cut-outs punched out and only
one washer.
the DLFC flow listed in Table 1-1. Combine the different washers so they
add up to the necessary flow (e.g., 70 GPM would be (2) 25 GPM washers
and (1) 20 GPM washer). Each washer is labeled with the flow it is sized
for.

3.5.12 DUPLEX 2.0 & 3.0 SOFTENER Drain Line Flow Controller
Units with 3 valves (continued):

o Make sure the numbers on the washers are facing down, and punch out
the same number of holes in the disk, as there are washers.

Section 3:

INSTALLATION
MULTI-MEDIA &
ACTIVATED CARBON
FILTERS


3.5.13 MULTI-MEDIA & ACTIVATED CARBON FILTERS Valve
and Piping Installation
Figure 3.5.13.1A: Piping Arrangement for SIMPLEX FILTER
NOTE: MULTIPLE TANK SYSTEMS typically have all filters piped in

PARALLEL


3.5.13 MULTI-MEDIA & ACTIVATED CARBON FILTERS Valve
and Piping Installation continued
control valve.
1.5 or 2 valve units only: Install the valves upper disperser to the bottom of
the valve using its instruction sheet (both supplied with the valve).
Carefully thread the control valve clockwise into the center opening in the top of
the tank. On 16-18 diameter units with 1 valves, first install the supplied tank-
to-valve bushing.
leverage or apply additional torque.
The manufacturer recommends installing a manual bypass line connecting the

common inlet and outlet lines so that the filter system can be bypassed if not in
use.
drain line flow control (DLFC).
Connect the open port of the DLFC housing to an open floor drain. Do not reduce
the pipe or tube size of the drain port connection. Make as short a run of drain
piping as possible. If it is necessary to run the drain line overhead, consult
technical support for recommendations.
main water supply. Open a filtered water tap and let it run a few minutes or until
the system is free from foreign material that may have resulted from the
installation. Once flushed, close the water tap and bypass valve, and open the
inlet valve (leave outlet shut). Proceed with startup instructions in the next
section.


3.5.14 MULTI-MEDIA & ACTIVATED CARBON FILTERS Drain
Line Flow Controller (DLFC)
10-18 Multimedia Filters and 10-21 Activated Carbon Filters:

o Note the required Backwash / Rapid Rinse flow DLFC in section 2.5.7
2.5.8 System Specifications for Multi-Media Filters and Activated
Carbon Filters. Out of the bag of in line flow control (DLFC) washers,
choose the one with this flow stamped on it (flows are in hundredths of a
GPM; i.e. 500 = 5 GPM).
housing, as shown in Figure 3.5.14.1A - 2 Valve DLFC Washer
Installation below. Make sure the numbers on the washer are facing out.
Figure 3.5.14.1A - 2 Valve DLFC Washer Installation
21-36 Multimedia Filters and 24-36 Activated Carbon Filters:

Reference Figure 3.5.14.1B - 2 Valve DLFC Washer Installation on the next
page and configure the DLFC housing using the following procedures:
drawing, the flat disc is shown with all four cutouts punched out and only
one washer.
the DLFC flow listed in Table 1-1. Combine the different washers so they
add up to the necessary flow (e.g., 70 GPM would be (2) 25 GPM washers
and (1) 20 GPM washer). Each washer is labeled with the sized flow.


3.5.14 MULTI-MEDIA & ACTIVATED CARBON FILTERS Drain
Line Flow Controller (DLFC) continued
o Make sure the numbers on the washers are facing down, and punch out
the same number of holes in the disk as there are washers.
smaller connection on the right side of the 1 valve, on the left side of the
1.5 valve, or on top of the 2 valve, as observed from the front (where the
controller is mounted). Make sure that the arrow on the housing is
pointing away from the valve. For 21 or 24 multimedia filters, the
supplied 1 x 2 FNPT bushing must be installed first.

Section 3:
STEP 6
MEDIA LOADING
SOFTENERS
& FILTERS

3.6 STEP 6 MEDIA LOADING
WARNING! WARNING! WARNING!

PROPER PROTECTIVE EQUIPMENT MUST BE WORN WHEN INSTALLING
MEDIA. PERSONNEL HANDLING MEDIA MUST WEAR A DUST MASK OR
RESPIRATOR FOR LUNG PROTECTION AND GOGGLES FOR EYE
PROTECTION. REFER TO MATERIAL SAFETY DATA SHEET (MSDS) FOR
COMPLETE INFORMATION .
INSTALLATION OF MEDIA
Place the softener tanks on a firm foundation as close to the floor drain as
possible, and level the vessels.
A riser tube distributor assembly has been shipped in each softener or filter
vessel.
Inspect the slotted basket (bottom distributor) to be sure it is not damaged. Also
make sure that the top of the riser pipe is flush with the top of the tank flange
when the basket is in the middle of the tank and flat on the bottom.
WARNING!!! BEFORE POURING ANY MEDIA INTO TANKS:
Cover the top of the riser pipe with tape or a plastic cap to prevent
gravel and resin from getting inside the riser pipe.
Fill the tank about 1/3 full with water. Center the riser tube distributor
assembly in the top opening of the fiberglass tank.
Make or buy a large funnel to prevent the gravel from spilling
WARNING!!!! Add water to filter vessel to cover lower manifold before

adding media. This will help to level media, expel air from media, and
reduce dust exposure.
To avoid displacement of water in multi-vessel systems, add each layer

of media to all vessels. Example: Add layer #1 to all vessels, then add
layer #2 to all vessels, and continue until all media has been added to all
vessels.


Figure 3.6.1A: Multi-Media & Activated Carbon vessels, riser tubes, and media
Multimedia Filters: Fill the tank about 1/3 full with water. Center the riser tube
distributor assembly in the top opening of the fiberglass tank.. Pour the proper
quantity of 1/8 x 1/16 (#4) gravel (see section 2.5.7 System Specifications for
Multi-Media Filters ) into the vessel. Level the gravel as best as possible,
making sure that all of the laterals or strainer slots are covered. Pour the
quantity of #8-12 garnet into the tank, and level. Load and level the #30-40
garnet. Load and level the #20 gravel. Load and level the anthracite. Fill the tank
with water and soak the media for 2 hours.
Activated Carbon Filters: Pour the proper quantity of 1/8 x 1/16 (#4) gravel
(see section 2.5.8 System Specifications for Activated Carbon Filters) into
the vessel. Level the gravel as best as possible, making sure that all of the
laterals or strainer slots are covered. Using the same funnel, pour the quantity of
carbon into the tank and level. Fill tank with water & soak the media for 2 hours.


Figure 3.6.1B: Softener vessel, riser tube, and media
Water Softeners: Pour the proper quantity of 1/8 x 1/16 (#4) gravel (see
section 2.6.7 2.6.10 System Specifications for Simplex, Duplex and Twin
Softeners) into the vessel.
NOTE: 9 and 12 vessels do not use the 1/8 x 1/16 (#4) gravel underbed.
Level the gravel as best as possible, making sure that all of the laterals or
strainer slots are covered. Using the same funnel, pour the quantity of cation
resin or filter media into the fiberglass tank. For softeners, fill the tank with water
and soak the resin for at least 2 hours.

Section 3:
STEP 7
INSTALLATION
CHECKLIST
SOFTENERS
& FILTERS

3.7 STEP 7 INSTALLATION CHECK-LIST

NOTE: Initial Start-Up must be performed by Authorized Factory
Technician such as trained Nalco Services personnel - otherwise
the Equipment Guarantee/Warrantee will be Null and Void.
If the filter is already installed and operating upon your arrival,
contact the Nalco Sales Representative or NGES at 630-848-3387 before
proceeding.
MANUAL ISOLATION VALVES installed on Inlet, Outlet & Drain?
BACKWASH FLOW CONTROLLER installed with FLOW
WASHERS inside?
MEDIA loaded into vessel(s), WATER first, then underbedding
(1/4 x 1/8) gravel, then MMF or Activated Carbon or Softening
Resin?
FAX COMPLETED
VESSEL(S) filled to top flange TO:
with water630-305-1800
and caps installed and
secured?
ATTN:
CONTROL VALVE NGESBODY securedHELP to top ofDESK
tank, all BOLTS /
FLANGES tightened?
CONTROL VALVE wired to TRANSFORMER, Transformer wired
to uninterrupted 120 VAC supply?
INLET PIPING connected to INLET port of Control Valve of LI-
Series system, arrow going in direction of flow?
OUTLET PIPING connected to OUTLET port of Control Valve of
Li-Series System, arrow going in direction of flow?
DRAIN PIPING connected to DRAIN port of Control Valve of LI-
Series System, arrow going in direction of flow?
All PIPING properly secured to avoid movement?
EDUCTOR PORT filled with proper color eductor (Softeners) or
capped (Filters)?
COMMUNICATION CABLES connected from Control Valve to

Control Valve on multi-tank systems?
FLOW METER installed in OUTLET piping and wired to Control
Valve on Volume-based single and multi-tank systems?

Section 3:
STEP 8
PROGRAMMING &
COMMISSIONING
SOFTENERS
& FILTERS


3.8 STEP 8 START-UP & PROGRAMMING
3.8.1 START-UP & COMMISSIONING GUIDE
Use this matrix to figure out exactly which system they have.
Most important- MODE, TANK SIZE, PIPE SIZE (write this down).
Single & Twin: see next page 98. Duplex: see page 99.
* If no model/part number is provided: see page 98.


3.8 STEP 8 Start-Up & Programming
If they do not provide a model/part number:
2. Ask them how many fiberglass tanks-
If 1 tank, it is a (single) time clock go to question 5-

If 2 tanks, it is a (duplex or twin)
3. How many valve heads?
4. If each tank has its own valve head it is a (duplex) system

If there is only one valve that runs both tanks it is a (twin) system
5. What size plumbing goes into the valve head?
Single
1 = 2750 fleck time clock (page 3)
1.5 = 2850 fleck time clock (page 3)
Duplex
1 = 2750 fleck valve with 3200 NT timers (page 4)
1.5 = 2850 fleck valve with 3200 NT timers (page 4)
Twin
1 = 9000 fleck valve w/mechanical meter & capacity wheel (next page)
1.5 = 9500 fleck valve w/mechanical meter & capacity wheel (next page)
6. What is the diameter of the fiberglass vessel or vessels? This is to

determine system capacity.
7. Once you know the system, plumbing size, and capacity- find the unit on
the charts. Page 99 is for single and twin systems. Page 100 is for
duplex systems.


SINGLE: See page 5-6 to set the timer
TWIN: See page 7-8 to set the timer


DUPLEX: 1 & 1.5: See pages 9-11 to program
DUPLEX: 2 & 3: See pages 9-11 to program


3.8.1 START-UP & COMMISSIONING GUIDE SINGLE UNITS
SINGLE UNIT TIMER DETAILS:
SINGLE UNIT REGENERATION TIMER SETTINGS:
The regeneration pins and spaces must be set according to the regeneration
cycle times chart on page 99-100.
1. The regeneration wheel can be found on the back of the timer assembly.
Open the timer like a door and the regeneration wheel will be visible. There
are 2 black clips in the center of the wheel, squeeze them together to remove
the wheel from the timer assembly. Refer to chart on page 3 for cycle times.
2. Each pin and each space represents 2 minutes of time.
3. The first set of pins = backwash- Find backwash time on chart (page 99-
100).
4. The first set of spaces = brine draw plus slow rinse. Find brine draw and
slow rinse times add them together. Find times on chart (page 99-100).


3.8.1 START-UP & COMMISSIONING GUIDE SINGLE UNITS
5. The second set of pins = rapid rinse- Find rinse time on chart (page 99-100).
6. The second set of spaces = refill cycle. Find refill time on chart (page 99-
100)
7. The final 2 pins reset the timer wheel- they must remain in place. Always
leave the two pins at end of regeneration cycles. The unit will stay in refill
cycle if these 2 pins are missing.
8. Once the cycle times are set replace the regeneration wheel. Close the timer
and set the time. You must push the red button to set the time of day. Align
the time of day arrow to the actual time right now.
9. Decide how often the unit will regenerate. There is a wheel in the lower right
corner of the timer with 7 clips on it. If the clip is pushed down towards the
outside of the wheel, the unit will regenerate on that day. If the clip remains in
the up position, the unit will not regenerate on that day. Single units are
preset to regenerate only at 2 AM only. This cannot be changed. If they want
to regenerate at some other time, they must modify the time of day to achieve
this.
10. If you want to run a manual regeneration, do not continuously turn the
regeneration wheel. Turn it just a little bit until the micro-switch closes on the
first set of pins (backwash) and let it go. Once you start the regeneration, the
regeneration timer motor takes over.
11. If you want to manually cycle the valve through all the steps, initiate the
regeneration. Turn the wheel to each regeneration step. Allow the piston
drive motor to stop before moving the timer to the next regeneration step. If
you continuously turn the wheel, you will throw the valve out of sequence with
the timer.
12. If you throw the unit out of sequence, keep turning the wheel until the piston
goes all the way in towards the valve. Unplug the unit from the wall. Turn the
regeneration wheel until the micro-switch armature is on top of the first set of
pins (backwash). Then plug the unit in and let it finish the regeneration. This
will put the timer in sync with the piston drive motor.


3.8.1 START-UP & COMMISSIONING GUIDE TWIN UNITS
TWIN UNIT REGENERATION TIMER DETAILS:
TWIN UNIT REGENERATION TIMER SETTINGS:
The regeneration pins and spaces must be set according to the regeneration
cycle times chart on page 3.
1. The regeneration wheel can be found on the back of the timer assembly.
Open the timer like a door and the regeneration wheel will be visible. There
are 2 black clips in the center of the wheel, squeeze them together to remove
the wheel from the timer assembly. Refer to chart on page 3 for cycle times.
2. Each pin and each space represents 2 minutes of time.


3.8.1 START-UP & COMMISSIONING GUIDE TWIN UNITS
3. The first set of pins = backwash. Find backwash time on chart (page 99-
100).
4. The first set of spaces = brine draw plus slow rinse. Find brine draw and
slow rinse times, add them up together. Find times on chart (page 99-100).
5. The second set of pins = rapid rinse. Find rinse time on chart (page 99-100).
6. The second set of spaces = refill cycle. Find refill time on chart (page 99-
100)
7. The final 2 pins reset the timer wheel. They must remain in place. Always
leave the two pins at end of regeneration cycles. The unit will stay in refill
cycle if these 2 pins are missing.
8. If you have a TWIN unit you have to set the capacity wheel on the front of the
timer as well. Take the unit capacity and divide it by the grain per gallon
hardness of the incoming water, this will give you gallon capacity. Pull out
and turn the clear gallon capacity wheel until the white dot coincides with the
gallon capacity of your system on the clear wheel.
(Example: 30,000 Grain Capacity / 7 Grains Per Gallon = 4,285 Gallon capacity)
9. If you want to run a manual regeneration, do not continuously turn the

regeneration wheel. Turn it just a little bit until the micro-switch closes on the
first set of pins (backwash) and let it go. Once you start the regeneration, the
regeneration timer motor takes over.
10. If you want to manually cycle the valve through all the steps, initiate the
regeneration. Turn the wheel to each regeneration step. Allow the piston
drive motor to stop before moving the timer to the next regeneration step. If
you continuously turn the wheel, you will throw the valve out of sequence with
the timer.
11. If you throw the unit out of sequence, keep turning the wheel until one
of the indicator arrows is pointing to backwash. Unplug the unit from
the wall. Turn the regeneration wheel until the micro-switch armature is
on top of the first set of pins (backwash). Then plug the unit in and let it
finish the regeneration. This will put the timer in sync with the piston
drive motor.


3.8.1 START-UP & COMMISSIONING GUIDE DUPLEX UNITS
If they have a duplex system with 3200 NT timers they must check a few wiring
details.
Wire transformer as shown in illustration above. Flow meter must be plugged

into one of the units (this will be the lead unit).


The communication cables (standard phone cables) must be wired exactly as

illustrated in the diagram above- (IN from lead to the OUT on lag / OUT of
the lead to the IN on lag).
The control with the flow meter plugged into it must be programmed as the LEAD
unit, if it is not, the unit will never register flow.
Now start programming-
Start by programming the LAG unit, the control without the flow meter wired to
it.
Here is a step by step procedure on how to program a duplex system:
Walk up to the LAG unit and begin programming. Change the time on the
screen to 12:01PM by using the set up and set down arrow keys. Press and
hold both up and down arrows at same time for 5-10 seconds. This will
give access to the program screens. When programming, use the arrow
keys to change the field and the extra cycle button to lock it in.


1. Valve model- choose according to plumbing size.
1 = [2750]
1.5 = [2850]
2 = [2900]
3 = [3900]
2. Regeneration style: Choose [dF] for down flow. Press the extra cycle button.
3. System type: Choose [7FI] for duplex. Press the extra cycle button.
4. Valve position: The first unit you program (without meter) defaults to [LAG]
press the extra cycle button.
5. Remote signal start: [RsOf] default. Press the extra cycle button.
6. Display format: [U- - 1] for US gallons or [U- - 4] for Liters press the extra
cycle button.
7. Unit Capacity: Resin quantity x 30 (example [C300] would be 10 cubic feet).

If you dont know how much resin, measure the diameter of the tank and refer
to the chart on page 4.
8. Capacity Safety Factor: [cF-0] this number is a reduction of capacity in %.

Press the extra cycle button.
9. Regeneration time: [2:00]. Press the extra cycle button.
10. Regeneration day override: [AOFF]. Press the extra cycle button.
11. Backwash time: [1 - ??]. Refer to chart on page 4 for backwash time. Press
the extra cycle button.
12. Brine draw + slow rinse: [ 2 - ??]. Refer to chart on page 4 for brine
draw/slow rinse time. Press the extra cycle button.
13. Rapid rinse time: [ 3 - ??]. Refer to chart on page 4 for rapid rinse time.


14. Refill time: [ 4 - ??]. Refer to chart on page 4 for refill time. This is very
important to get correct, if not, the unit will not fully regenerate. Press the
extra cycle button.
15. [5OFF]: Leave this off. Press the extra cycle button.
16. [AROF]: Leave this as is. Press the extra cycle button.
17. [E-92]: Leave this at default. Press the extra cycle button.
18. [cPoF]: Leave this at default. Press the extra cycle button.
19. Line frequency. Leave at [LF60]. Press the extra cycle button.
20. The LAG unit will show CALC on the screen, this is normal.
Walk up to the LEAD unit and begin programming. Change the time on the
screen to 12:01PM by using the set up and set down arrow keys. Press and
hold both up and down arrows at same time for 5-10 seconds. This will
give access to the program screens. When programming, use the arrow
keys to change the field and the extra cycle button to lock it in.
21. Valve model- choose according to plumbing size.
1 = [2750]
1.5 = [2850]
2 = [2900]
3 = [3900]
22. Regeneration style: Choose [dF] for down flow. Press the extra cycle button.
23. System type: Choose [7FI] for duplex. Press the extra cycle button.
24. Valve position: The second unit you program (with meter) needs to be the
[LEAD]. Press the extra cycle button.
25. Remote signal start: [RsOf] default. Press the extra cycle button.
26. Display format: [U- - 1] for US gallons or [U- - 4] for Liters press the extra
cycle button.


27. Unit Capacity: Resin quantity x 30 (example [C300] would be 10 cubic feet).
If you dont know how much resin, measure the diameter of the tank and refer
to the chart on page 4.
28. Capacity Safety Factor: [cF-0] this number is a reduction of capacity in %.

29. Hardness setting: Total hardness of incoming water in grains per gallon.
(Parts per million / 17.1 = grains per gallon) [H - ??]. ONLY ON LEAD
UNIT.
30. Regeneration time: [2:00]. Press the extra cycle button.
31. Regeneration day override: [AOFF]. Press the extra cycle button.
32. Backwash time: [1 - ??]. Refer to chart on page 4 for backwash time. Press
the extra cycle button.
33. Brine draw + slow rinse: [ 2 - ??]. Refer to chart on page 4 for brine
draw/slow rinse time. Press the extra cycle button.
34. Rapid rinse time: [ 3 - ??]. Refer to chart on page 4 for rapid rinse time.
35. Refill time: [ 4 - ??]. Refer to chart on page 4 for refill time. This is very
important to get correct, if not, the unit will not fully regenerate. Press the
extra cycle button.
36. [5OFF]: Leave this off. Press the extra cycle button.
37. [AROF]: Leave this as is. Press the extra cycle button.
38. [E-92]: Leave this at default. Press the extra cycle button.
39. [cPoF]: Leave this at default. Press the extra cycle button.
40. Flow meter size = [ FF- plumbing size ] ONLY ON LEAD UNIT.
41. Line frequency. Leave at [LF60]. Press the extra cycle button.
42. The LEAD unit will show CALC for about 30 seconds.


Congratulations! You have programmed a duplex softener. Now the screens

should show the time and gallon capacity remaining. To set the time, use the up
and down arrow keys.
If CALC remains on the display for over 5 minutes, inspect communication cables
and reprogram.
To manually initiate regeneration press and hold the extra cycle button for 5-10
seconds on the unit that is in service.
If you need help

Section 4: Maintenance
4.1 Preventative Maintenance
4.1.1 GENERAL MAINTENANCE GUIDELINES
A. MAINTENANCE AND SAFETY
Before working on this system, operators must be familiar with the
General Safety Precautions at the beginning of this manual.
B. VESSELS
The vessel for this system is fiberglass and requires no maintenance. If
exposed to freezing temperatures, the vessel and its piping must be
insulated and heated, or shut down and drained.
C. PIPING
Operators should check all piping connections periodically for leaks. Any
flanges used on the piping may require periodic tightening to prevent
leaks. If the system is operated within the temperature and pressure
limits, little maintenance is required
D. MANUAL VALVES
Manual valves should be operated through their full range, at least every 6
months, to assure they function properly and are free of debris.
E. PRESSURE REGULATORS
Any pressure regulators used in conjunction with this system should be
inspected occasionally to assure they are set properly.
F. LEAK CHECKING
Operators should be alert for leaking pipes, valves, and components.
Detecting and repairing a leak while it is still small may prevent lengthy
downtime later.
G. CHECK MEDIA LEVEL & CONDITION

Isolate filter system from all water sources and de-energize power supply.
Drain water from system. Remove vessel cap and gasket. Inspect media.
Media should be loose and clean. Remove any loose debris or small
amount of accumulated cake. Add or replace media as necessary.
Replace vessel cap gasket and secure cap. Close filter system drain,
open all water supply valves and energize power supply. Return system
to service with manual backwash.

5.1 Troubleshooting
5.1.1 TROUBLESHOOTING PROTOCOL
The following protocol is recommended for troubleshooting an LI-Series System:
1) Contact the Nalco Sales Representative to perform an initial

interview on the problems and status of the filter.
2) Visit the customers site and stand in front of the unit
3) Perform an initial survey around the unit to determine if any

external factors are affecting the performance (electrical, water,
drain connections). Contact NGES Tech Support at any time
630-848-8837 with help in surveying the unit.
4) Interview the any personnel at the customers site that can also
provide information on the problems and status of the filter.
5) Review the TROUBLESHOOTING MATRIX to determine if the

problem is identifiable. Contact NGES Tech Support at any time
630-848-8837 with help in using the Troubleshooting Matrix.
6) If the problem is NOT identifiable. Contact NGES Tech Support

at any time 630-848-8837 for support.
7) If the problem is identifiable, determine if it can be remedied on this

service visit, or if it will necessitate additional items (another visit,
spare parts, technical assistance from the factory). The factory and
NGES Tech Support will need the TROUBLESHOOTING
REPORT to assist in solving the problem.
8) Complete a SERVICE REPORT of the findings and information

gathered during the Troubleshooting Report and note the
necessary additional actions. This Service report can be printed
immediately and left with the customer. Additional copies should
be sent to the Nalco Sales Representative. The factory and NGES
Tech Support will need the SERVICE REPORT to assist in
solving any problems.
If you need help

5.1 Troubleshooting
5.1.2 OPERATING PROBLEMS
Problem areas in operation included breakdown of the resin, iron fouling,

presence of suspended material in the source water, and unstable water.
Resin Breakdown
The synthetic resins will normally last 15 to 20 years, but certain
conditions can cause the resin to breakdown sooner. Oxidation by chlorine
is probably the most common cause of resin breakdown. When chlorine is
used to oxidize iron in the water, the chlorine should be removed before
the ion exchange unit.
Iron Fouling
Iron in the source water will seriously affect the ability of the resin to
remove the hardness ions. Ferrous iron can be oxidized during the
softening and precipitate out as iron oxide on the resin.
No amount of brine will remove the iron fouling. If the iron oxide is formed
before the exchange unit, it can be filtered out by the resin and removed
during the backwashing of the unit. Normally if the iron concentration in
the source water is high, iron removal is provided ahead of the exchange
unit to prevent fouling of the unit.
Suspended material
Turbidity, organic chemicals, and bacterial slimes seriously affect the resin
by coating it, resulting in the loss of some of the resins exchange
capacity. The best solution to this problem is the removal of the
suspended matter by the normal water treatment methods of coagulation,
sedimentation, and filtration before the softening process.
Unstable water
Any water that has been softened by the ion-exchange process will be
corrosive and will have to be stabilized to prevent corrosion from taking
place in the distribution system. The way to accomplish this is by adding
phosphates or other chemicals to reduce the corrosivity of the water.
If you need help

5.1 Troubleshooting
5.1.3 Troubleshooting Matrix:

Symptom Cause Remedy
1. Softener failed to regenerate a. Flow meter not registering flow a. Inspect flow meter wiring and internals for blockage
b. Capacity set too high in program b. Check capacity in program
c. Hardness set too low in program c. Verify and re-program hardness in grains per gallon
d. No-bypass valve failure (1" & 1.5" duplex) d. Cycle unit to verify solenoids energize, diaphragms close
e. Valve head failure e. Cycle valve(s) to verify that the motors run
2. Total hardness breakthrough a. No salt in brine tank a. Inspect brine tank for salt or salt bridging
b. Capacity set too high in program b. Check capacity in program
c. Flow meter not working c. Inspect flow meter
d. Refill time set too low-not enough salt d. Set refill cycle correctly for proper salt dose
e. No-bypass assembly failure (1" & 1.5" duplex) e. Cycle unit to verify solenoids energize, diaphragms close
f. Softener is oversized for the application f. Make sure the system was properly sized
3. Partial hardness breakthrough a. Low flow channeling a. Increase flow above 0.5gpm per cubic foot of resin
b. Capacity set too high in program b. Decrease capacity in program if needed
c. Hardness set too low in program c. Increase hardness setting if needed
d. Bypass ball valve open slightly d. Inspect bypass valves, make sure they are closed
e. Refill time set too low, not enough salt e. Increase refill time for proper salt dose
4. Not refilling brine tank a. Refill time set too low a. Increase refill time in program
b. Someone expects to see more water b. Double check refill time vs refill rate
5. Overflowing brine tank a. Plugged drain line a. Drain needs to be open to atmosphere
b. Valve stuck in refill cycle, out of sequence b. Re-home the unit to service
c. Lower piston not cycling during regen c. Cycle unit, inspect lower drive motor
d. Refill time set too high d. Lower refill time
e. Brine valve failure e. Cycle into service, if still refilling replace brine valve
f. No-bypass assembly failure (1" & 1.5" duplex) f. Cycle unit to verify solenoids energize, diaphragms close
6. Unit not drawing brine a. Plugged drain line a. Drain must be open to atmosphere
b. Insufficient inlet pressure b. Check inlet pressure, minimum 20psi
c. Injectors plugged c. Inspect injectors for debris
d. Internal valve leak to service d. Inspect operation of valve motors and pistons
e. No-bypass assembly failure (1" & 1.5" duplex) e. Cycle unit to verify solenoids energize, diaphragms close
7. Resin in the drain line a. No drain line flow control installed a. Inspect drain for drain line flow control
b. Oversized drain line flow control b. Inspect drain line flow control washer
c. Air in the incoming water line c. Check for air eliminator control
d. Water temperature below 40*F d. Lower drain line flow control washer size
8. Resin in the service line a. Cracked distributor/riser tube a. Open tank, inspect riser tube for cracks
b. Unit plumbed in backwards b. Refer to install drawing for correct plumbing

5.1 Troubleshooting
5.1.3 Troubleshooting Matrix continued
Symptom Cause Remedy
9. Pressure drop across unit a. Lower piston not opening a. Inspect lower piston
b. Iron fouled resin bed b. Inspect resin for fouling
c. Clogged valve head c. Open tank, inspect for blockage, foreign material in valve
10. Water flowing to drain a. Seal and spacer failure in valve head a. Rebuild valve
b. Stuck in a regen step b. Cycle to service
c. Programmed incorrectly c. Reprogram unit
11. Valve continuously cycling a. Wire disconnected from home switch a. Re-wire harness to switch and control board
b. Programmed incorrectly, wrong valve b. Re-verify program is correct for valve
c. Home switch failure c. Check for continuity on switch
12. Used too much salt a. Refill time set too high a. Decrease refill time
13. cErr (error code on 3200NT) a. Missing or bad communication cable (duplex) a. Reconnect communication cables IN to OUT, OUT to IN
communiction error b. Communication cable wired wrong (duplex) b. Double check wire diagram, IN to OUT, OUT to IN
c. System type programmed incorrectly (duplex) c. Make sure both units are 7FI in system type program
d. Both units are programmed as LAG (duplex) d. Make sure unit with flow meter is LEAD, other is LAG
14. pErr (error code on 3200NT) a. Two units programmed as LEAD or LAG (duplex) a. Unit without flow meter is LAG, with meter LEAD
b. System type programmed wrong (duplex) b. Duplex is 7FI system type
15. LOC (code on 3200NT) a. System in regeneration a. Wait until regen is over to re-program or regenerate
16. Calc (code on 3200NT) a. Valves are homing themselves (temporarily) a. Program both units, Calc should clear, verify wiring
If recommended remedy fails, Contact NGES Tech Support

at 630-848-8837 for additional support.
If you need help

5.1 Troubleshooting
5.1.4 Service Report - Elution Study PSR
5.1.4.1 Elution Study Instructions

General
The worksheets are protected to avoid accidently erasing or reformatting parts of the PSR. If
there is a need to change a protected cell, the protection can be turned off by going toTools--
>Protection-->Unprotect Sheet. A password is not required. Note that changes to the
formatting may dramatically effect the way the documents print.
PSR Tab
Customer data can be entered into the top section.
Salometer readings should be entered into the yellow highlighted areas to the right of the
graph. There are two columns of data for cases where an elution study is being performed on
a two-vessel system.
The graph will auto-update as data is entered.
Recommendation and comments should be entered in the appropriate sections below the
graph.
The "Print" button on the PSR will print the PSR tab and the Survey tab, and it will not print the
elution study data to the right of the chart.
Survey Tab
Enter the requested data into the underlined fields.
Volume data will auto-calculate based on the flow rate and time entered.
Data Tab
Print this page to use while performing the elution study.
The left half of the page collects data that will determine flow rates through different stages of
the regeneration cycle. The right half of the page collects the data required to build the
performance graph.
Left side: Enter the start time, finish time, and volume collected (L or gals, but not both) for
each sample collected. The flow rate data can be electronically entered on the Data tab to
auto-calculate the flow rates, which you can carry over to the Survey tab.
Right side: Write down the time on the stopwatch for each of your readings using three minute
intervals. Record salomter readings until the rinses are finished, and record conductivity
readings after the rinse stages to determine how well the vessel has been rinsed. Effluent
conductivity should approximately match the incoming conductivity to signal a well rinsed resin
bed.
Resources Tab
Compare the elution study data with the diagrams on the first page of this tab to determine
recommendations for optimizing the exchange unit regeneration.
The second page has common conversions for salt solutions. If a salometer is not available,
other means of measuring brine concentration can be used.

5.1 Troubleshooting
5.1.4.2 BLANK Elution Study PSR Cover Page:

5.1 Troubleshooting
5.1.4.3 BLANK Elution Study PSR Survey Page:

5.1 Troubleshooting
5.1.4.4 BLANK Elution Study PSR Data Page:

5.1 Troubleshooting
5.1.4.5 BLANK Elution Study PSR Resources Page 1:

5.1 Troubleshooting
5.1.4.6 BLANK Elution Study PSR Resources Page 2:

5.1 Troubleshooting
5.1.5 Manufacturer Spare Parts Listings
REPLACEMENT/SPARE PARTS LIST

Duplex Alternating Softener Systems With 1 and 1.5 Valves
If you need help

5.1 Troubleshooting
5.1.6 Manufacturer Spare Parts Listings
REPLACEMENT/SPARE PARTS LIST

Duplex Alternating Softener Systems With 2 and 3 Valves
If you need help

APPENDIX A
GLOSSARY
OF
TERMS
&
DEFINITIONS

APPENDIX A
GLOSSARY OF TERMS & DEFINITIONS
BACKWASH: The counter-current flow of water through a resin bed (i.e. in at the bottom of the
vessel, out at the top) to clean and reclassify the bed after exhaustion.
BED EXPANSION: The effect produced during backwashing: the resin particles become
separated and rise in the column. The expansion of the bed due to the increase in space
between resin particles may be controlled by regulating backwash flow.
BED: The resin contained in a vessel.
BRINE: Water saturated with salt.
CAPACITY: The ability of the resin to remove hardness, measured in kilograins per cubic foot.
CONCENTRATION: The amount of substance in weight, moles, or equivalents contained in a

unit volume.
CONTAMINANT: Any foreign component present in another substance; e.g., anything in water
that is not H20 is a contaminant.
CYCLE: A complete sequence of operation. For instance, a complete softener cycle of would
involve: Service, Backwash, Brine In / Slow Rinse, Fast Rinse, Brine Tank Refill, and back into
Service.
EFFLUENT: The solution which emerges from a system unit.
EXHAUSTION: The state in which the resin is no longer capable of removing enough hardness
from the feed water.
FINES: Extremely small particles of ion-exchange resin.
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.
FREEBOARD: The space provided above the resin bed in an ion-exchange column to allow for
expansion of the bed during backwash.
GRAINS/GALLON: An expression of concentration of material in solution. One grain per gallon

is equivalent to 17.12 parts per million.
GRAIN: A unit of weight; 0.0648 grams; 0.000143 pounds.
HARDNESS: The scale-forming and lather-inhibiting qualities which water, high in calcium and
magnesium ions, possesses.

APPENDIX A
GLOSSARY OF TERMS & DEFINITIONS
INFLUENT: The solution which enters a system unit.
ION EXCHANGE: A process by which certain undesired ions of given charge are removed from
solution with an absorbent, being replaced in the solution by desirable ions of similar charge
from the absorbent.
ION: Any particle of less than colloidal size possessing either positive or negative electric
charge.
KILOGRAIN: A unit of weight; one thousand grains. There are seven kilograins per pound.
MEDIA: The material (resin, carbon, quartz) that is used in a fluid-treatment vessel.
MINERAL: A natural inorganic substance having a definite chemical composition and structure.
RAW WATER: Untreated water from wells or from surface sources.
REGENERATION: The process by which a system is conditioned to ready it for another service
cycle.
RESIN: Typically, a synthetic plastic bead with attached ions that will exchange (trade places
with) with other ions in a process feed stream. Used in ion exchange applications.
RINSE: The final step in a unit regeneration, in which water is flushed through the unit until the
effluent quality is proper.
SCALE: The precipitate that forms on surfaces in contact with water.
SOFTENING: The removal of hardness - calcium and magnesium - from water.
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.
TDS: Total Dissolved Solids, in parts per million (ppm.
THROUGHPUT The amount of solution passed through an exchange bed before
VOLUME: exhaustion of the resin occurs.

APPENDIX B
LIMITED WARRANTY

APPENDIX C
Equipment
Specifications
LI-Series

UltraSand
Multimedia Filters

APPENDIX C
Equipment Specifications
UltraSand LI Series Multimedia Filters
Model NFZMS
General Description:
UltraSand LI-Series multimedia filters reduce the amount of suspended solids in the
feedwater by filtering the water through a multi-layered filter bed. LI Series multimedia
filter performance for turbidity or particulate removal depends on the flow rate and size
of the particulates. At 10 gpm/ft2, 90% turbidity removal is typical, while at 8 gpm/ft2,
96% turbidity removal is typical. These ratings are valid for particle sizes of 40 microns
and larger. Removal of particulates smaller than 40 micron can be achieved by
operating at lower flow rates and/or by utilizing a polymer feed to coagulate the smaller
particles.
The filters contain five separate layers of media. Two underlying layers support the top
three active filter layers. Media specific gravity and size gradations account for the
natural layering, which occurs within the filter following backwashing. This layered
media profile provides a higher sediment holding capacity as compared to conventional
single and dual media sand filters. The larger incoming particles are trapped on the
upper layers allowing the smaller particles to continue through the bed where they are
trapped in the lower layers. This depth profile of the bed increases the filtering surface
area and the capacity of the unit.
Mechanical Description:
The LI-Series vessel is a corrosion resistant composite, constructed of a polyethylene
shell wound with continuous fiberglass fibers. The shell height is designed to allow for
expansion of the media during the regeneration cycle. The top vessel opening is used
for media loading and connection for the multiport control valve.
The filter is supplied with high quality filtration media and underdrain support media.
The support media ensures even flow distribution. The inlet diffuser evenly distributes
influent water and collects backwash water. The lower hub and lateral, or single point
distributor (depending upon tank size) collects effluent and distributes backwash water.
Each vessel is fitted with a top-mounted, five-cycle multiport control valve to accomplish
the operational steps of backwash and fast rinse cycles. The brass control valve
includes fixed and self-adjusting flow regulators to control flow rates during each
operational cycle. The valve seals are static o-rings and separated by precision
positioned spacers. The cycles of regeneration are accomplished with the movement of
a hydraulically balanced Teflon coated piston. The piston is the only moving part in the
main control valve.

Electrical Description:
The filter will regenerate based on time, which is initiated by a seven (7) day cycle timer
that can be set on any hour within a 24-hour period and initiated on any or all days in
the 7-day period. The operator can manually initiate regeneration at any time. No
water is available during the regeneration step and an extra cam and microswitch is
included to send a signal to downstream equipment during the regeneration mode.
Operational Description:
The LI-Series Multimedia filters have two modes of operation, service and regeneration.
While in the service mode, the filtered water is delivered to downstream equipment.
The regeneration mode is comprised of three steps: backwash, settle and rinse. The
backwash step expands the layers of media and removes trapped particulates. The
settle step allows the bed to settle and classify into discrete layers. The rinse step
flushes the bed and prepares it for the service mode.
Product Offering Overview:

Reference Maximum Flow Rate (gpm)
Model Number
(Diameter Pipe Size)
NFZMS010FXZFAX 10-1 5
NFZMS012FXZFBX 12-1.5 8
NFZMS021FXZFCX 21-2 24
Design Parameters:
Configuration Simplex
Sizing 10 gpm / ft2
Bed Depth 30 to 37 inches
Freeboard 65 to 100%
Capacities (Approximate) 0.5 lbs. / ft2
Backwash 15 gpm / ft2
Standard Product Ordering Information:
Model Number: NFZMS 012 F X Z F A X

Vessel Size
010 10 x 40
012 12 x 52
014 14 x 65
016 16 x 65
018 18 x 65
021 21 x 62
024 24 x 72
030 30 x 72
036 36 x 72
Vessel Design
F Non-Code
Controls
X NEMA 1
Assembly
Z Free standing
Regeneration
F 7-Day time clock
Inlet / Outlet Size

A 1 Available on 10 through 18 diameter units
B 1 Available on 12 through 21 diameter units
C 2 Available on 21 through 36 diameter units
Options
X None

General Specifications:
Pressure Vessel
Materials Composite polyethylene and fiberglass
Rating 100 psig
Support Free standing
Access Openings
For 1 Valve Units (1) 2 threaded
Process Connections Threaded brass
Distribution Systems
Upper Basket diffuser
Lower (underdrain)
10 through 18 diameter PVC basket strainer
Single row PVC hub and Schedule 80 PVC
18 through 36 diameter
slotted radials
Top Mount Valve
1 Fleck model 2750 brass construction
Controls Specifications:
Power 110 volt, 60 Hz, 10 Watts
Enclosure NEMA 1
Controller Fleck
Interface Communication Specifications:

Output 1 (RO Cutout) Contact closure indicates unit is in regeneration
Operating Limits:
Temperature
Maximum Feed Temperature 100OF
Minimum Feed Temperature 45OF
Pressure
Maximum Feed Pressure 100 psig
Minimum Feed Pressure 30 psig
Maximum Pressure Variability +/- 5 psig
If any of the operating conditions are not within the limits given, call Nalco Global
Equipment Solutions Technical Support at 800-323-8483 for the appropriate
recommendation and application assistance.

Process Influent Guidelines:
Parameter:
Suspended < 30 NTU
Solids
*If any of the feedwater parameters are not within the limits given, call Nalco
Global Equipment Solutions Technical Support at 800-323-8483 for the
appropriate recommendation and application assistance.
Regulations and Standards:

Pressure NSF and WQA
Vessels
Electrical NEMA 1
Documentation Package:
Storage, installation and operating instructions, shipping list
Documents
and spare parts list
Drawings General Arrangement (GA) and line wiring
Quality
Inspection check list / pick list
Documents

APPENDIX D
Equipment
Specifications
LI-Series

UltraCarb
Activated Carbon
Filters

APPENDIX D
UltraCarb LI-Series Carbon Filters
Model NFZCS
UltraCarb LI-Series carbon filters reliably remove chlorine from the feedwater by
filtering the water through a bed of activated carbon. Many processes like reverse
osmosis and demineralization must have the chlorine removed from their feedwater to
protect the membranes and resin from oxidative attack. The use of activated carbon
provides an effective means to protect equipment from chlorine exposure. Activated
carbon can also reduce the level of some organics in the feedwater by operating at one
half or less of the flow rate utilized for chlorine removal.
A gravel bed supports the single layer of activated carbon. Any trapped feedwater
suspended solids and carbon fines are easily removed during backwashing without
disrupting the gravel support bed.
The filter is supplied with high quality filtration media and underdrain support media.
The support media ensures even flow distribution. The inlet diffuser evenly distributes
influent water and collects backwash water. The lower hub and lateral, or single point
distributor (depending upon tank size) collects effluent and distributes backwash water.
the operational steps of backwash and fast rinse cycles. The brass control valve
includes fixed and self-adjusting flow regulators to control flow rates during each
operational cycle. The valve seals are static o-rings and separated by precision
positioned spacers. The cycles of regeneration are accomplished with the movement of
a hydraulically balanced Teflon coated piston. The piston is the only moving part in the
main control valve.
The filter will regenerate based on time, which is initiated by a seven (7) day cycle timer
that can be set on any hour within a 24-hour period and initiated on any or all days in
the 7-day period. The operator can manually initiate regeneration at any time. No
water is available during the regeneration step and an extra cam and micro switch is
included to send a signal to downstream equipment during the regeneration mode.

The LI-Series carbon filters have two modes of operation, service and regeneration.
While in the service mode, the treated water is delivered to downstream equipment.
The regeneration mode is comprised of three steps: backwash, settle and rinse. The
backwash step expands the layers of media and removes trapped particulates. The
settle step allows the bed to settle. The rinse step flushes the bed and prepares it for
the service mode.
Model Number: NFZCS 012 F X Z F A X
Vessel Size
010 10 x 40
012 12 x 52
014 14 x 65
016 16 x 65
018 18 x 65
021 21 x 62
024 24 x 72
030 30 x 72
036 36 x 72
Vessel Design
F Non-Code
Controls
X NEMA 1
Assembly
Z Free standing
Regeneration
F 7-Day time clock
Inlet / Outlet Size

Options
X None

Reference Maximum Flow
Model Number (Diameter- Pipe Rate (gpm)
Size)
NFZCS010FXZFAX 10-1 5
NFZCS012FXZFBX 12-1.5 8
NFZCS021FXZFCX 21-2 24
Design Parameters:
Sizing 10 gpm / ft2
26 to 30 inches, 12 x 40 mesh bituminous
Bed Depth
carbon
Freeboard 51 to 85%
15 lbs. / ft3 for Chlorine, 1 lbs. / ft3 for
Capacities (Approximate)
Organics
Backwash 10 gpm / ft2
Pressure Vessels
Rating 100 psig
Access Openings
Lower (underdrain)

slotted radials
Top Mount Valve
Enclosure NEMA 1
Controller Fleck

Contact closure indicates unit is in
Output 1 (RO Cutout)
regeneration
Operating Limits:
Temperature
Pressure

Parameter Limits
Suspended Solids < 5 NTU
Chlorine < 5.0 mg/L
Organics < 5.0 mg/L as O2 consumed
If any of the feedwater parameters are not within the limits given, call Nalco

Pressure Vessels NSF and WQA
Electrical NEMA 1
Storage, installation and operating
Documents
instructions, shipping list and spare parts list
Quality Documents Inspection check list / pick list

APPENDIX E
Equipment
Specifications
LI-Series

UltraSoft
TWIN Water
Softeners

APPENDIX E

UltraSoft LI-Series Twin Alternating Softeners
Model NFZST (Volume Initiated)
UltraSoft LI-Series water softeners reduce the hardness in feedwater using ion
exchange resin. The water softener vessel contains high quality cation resin in the
sodium form that removes hardness. Hardness will create scale on reverse osmosis
membranes, water heaters, boilers and other equipment if not removed. Calcium,
magnesium, and other cations removed by the resin are replaced with sodium ions.
The resin has a fixed capacity based on the pounds of salt used per cubic foot of resin
during regeneration. Flow rate, TDS and other factors will dictate the actual capacity of
the resin. When the capacity is exceeded, the resin will allow the hardness ions to pass
through the unit. Before the capacity is exceeded, the unit is removed from service and
regenerated with a solution of sodium chloride (brine). Completion of the regeneration
steps allows the water softener to be returned to the service mode
Two softener vessels are supplied with high capacity cation exchange resin and a
gravel support bed. The inlet diffuser evenly distributes influent water, collects
backwash water and introduces the brine regenerant solution. The lower hub and
lateral or single point distributor (depending upon tank size) collects effluent and
regeneration water as well as distributes the backwash water.
One vessel is fitted with a top-mounted, five-cycle multiport control valve to accomplish
the operational steps of backwash, brining, slow rinse, fast rinse and refill cycles for
both vessels. The brass control valve includes fixed and self-adjusting flow regulators
to control flow rates during each operational cycle. The valve seals are static o-rings
and separated by precision positioned spacers. The cycles of regeneration are
accomplished with the movement of a hydraulically balanced Teflon coated piston. The
piston is the only moving part in the main control valve.
A single salt storage tank (brine tank) is supplied as part of the softener system, which
is constructed of corrosion resistant polyethylene. The brine tank is equipped with an
automatic air-eliminator safety valve attached to the brine line and housed within a
protective chamber inside the brine tank to prevent damage during salt loading. The
brine valve will automatically open to educt the brine into the softener tank, close to
prevent eduction of air, and refill the brine tank with the proper amount of water
regardless of the salt level in the tank.

The dual tank configuration provides softened water during service. The system does
not have an internal by-pass valve, thus preventing raw water bypass during the
regeneration cycle. The system consists of one control valve, two mineral tanks, one
brine tank, resin and a gravel support bed for 12 diameter vessels and larger.
An electromechanical totalizing water meter initiates regeneration. The operator can
manually initiate regeneration at any time.
The water softeners have two modes of operation, service and regeneration. The
service mode delivers softened water to equipment downstream. Regeneration is
comprised of five steps; backwash, brine introduction, slow rinse, fast rinse and brine
refill. The backwash step removes trapped material and reclassifies the bed. The brine
introduction step strips hardness from the resin and converts the resin into the sodium
form. The rinse steps displace the brine with water and prepare the bed for the service
mode. The brine re-fill step adds the proper amount of water back into the brine tank to
dissolve the precise amount of salt for the next regeneration cycle.
These softeners operate in an alternating fashion. Only one softener will be in the
service mode or regeneration mode at any given time. When the preset volume of
water has been treated, the first softener will begin the regeneration mode and the
second softener will begin the service mode. The digital totalizing water meter is reset
to zero when each softener begins its regeneration mode. Additionally, the softeners
are regenerated with soft water derived from the softener in the service mode.

Maximum
Reference
Model Number Flow Rate
(Kgrains-Pipe Size)
(gpm)
NFZST007FXZNAX 15 15-1
NFZST012FXZNBX 39 60-1.5
NFZST021FXZNBY 55 180-1.5
NFZST024FXZNBY 57 240-1.5
NFZST024FXZNBZ 54 300-1.5

Design Parameters:
Configuration Twin Alternating
Model Number: NFZST 009 F X Z N A X
Vessel Size
007 7 x 44
009 9 x 40
010 10 x 54
012 12 x 52
014 14 x 65
016 16 x 65
018 18 x 65
021 21 x 62
024 24 x 72
Vessel Design
F Non-Code
Controls
X NEMA 1
Assembly
Z Free standing
Regeneration
N Electromechanical alternating, meter initiated
Inlet / Outlet Size

Resin Volume
X Standard resin volume Available on all units
Y Minimum resin volume Available on 21 and 24 diameter units
Z Maximum resin volume Available on 24 diameter units
Pressure Vessels
Rating 100 psig
Access Openings
For 1 Valve Units (1) 2 Threaded
Lower (underdrain)
slotted radials
Top Mount Valve
Enclosure NEMA 1
Controller Fleck

None
Operating Limits:
Temperature
Pressure


Parameter: Limit
Total Dissolved Solids 750 ppm as CaCO3
Suspended Solids 5 NTU
Chlorine 0.5 ppm
Organics 0.5 ppm as O2 consumed

Electrical NEMA 1
Documents

APPENDIX F
Equipment
Specifications
LI-Series

UltraSoft
SIMPLEX
Water Softeners

APPENDIX F
UltraSoft LI-Series Simplex Softeners
Models NFZSS (TimeClock or Volume Initiated)
The softener is supplied with high capacity cation exchange resin gravel support bed.
The inlet diffuser evenly distributes influent water, collects backwash water and
introduces the brine regenerant solution. The lower hub and lateral or single point
distributor (depending upon tank size) collects effluent and regeneration water as well
as distributes the backwash water.
the operational steps of backwash, brining, slow rinse, fast rinse and refill cycles. The
brass control valve includes fixed and self-adjusting flow regulators to control flow rates
during each operational cycle. The valve seals are static o-rings and separated by
precision positioned spacers. The cycles of regeneration are accomplished with the
movement of a hydraulically balanced Teflon coated piston. The piston is the only
moving part in the main control valve.

The single tank configuration provides softened water during service. The system is
equipped with an internal by-pass valve, which allows raw water bypass the softener
during the regeneration cycle. The system consists of one control valve, one mineral
tank, one brine tank, resin and a gravel support bed.
The water softeners come as either TimeClock or Volume initiated regeneration
systems. Timeclock initiated regeneration involves a timed regeneration that is initiated
by a seven (7) day cycle timer that can be set for any hour within a 24 hour period and
initiated on any or all days in the 7 day period. Volume initiated regeneration involves a
digital totalizing water meter initiates regeneration. In addition to either model selected,
the operator can manually initiate regeneration at any time.

Reference
Maximum Flow
Model Number (Kgrains-Pipe
Rate (gpm)
Size)
TimeClock Models
NFZSS009FXZFAX 19 30-1
NFZSS012FXZFBX 39 60-1.5
NFZSS018FXZFCX 81 150-2
NFZSS024FXZFBZ 54 300-1.5
NFZSS024FXZFCZ 91 300-2
NFZSS030FXZFEX 213 450-3

Volumetric Models
NFZSS009FPZVAX 19 30-1
NFZSS012FPZVBX 39 60-1.5
NFZSS018FPZVCX 81 150-2
NFZSS030FPZVEX 213 450-3
Model Number: NFZSS 009 F X Z F A X
Vessel Size
009 9 x 40
012 12 x 52
014 14 x 65
016 16 x 65
018 18 x 65
021 21 x 62
024 24 x 72
030 30 x 72
036 36 x 72
Vessel Design
F Non-Code
Controls
X NEMA 1
Assembly
Z Free standing

Regeneration
F 7-Day TimeClock
V Meter initiated
Inlet / Outlet Size

E 3 Available on 30 and 36 diameter units
Resin Volume
X Standard resin volume Available on all units
Y Minimum resin volume Available on 21 and 24 diameter units
Z Maximum resin volume Available on 24 diameter units
Design Parameters:
Pressure Vessels
Rating 100 psig
Access Openings
Lower (underdrain)
10 diameter through 18
PVC basket strainer
diameter w/ 1 pipe
18 diameter w/1 pipe Single row PVC hub and Schedule 80 PVC
through 36 slotted radials
Top Mount Valve

Enclosure NEMA 1
Controller Fleck

Output 1 (RO Cutout) Contact closure indicates unit is in regeneration
Operating Limits:
Temperature
Pressure

Parameter Limit
Chlorine 0.5 ppm
If any of the feedwater parameters are not within the limits given, call Nalco

Electrical NEMA 1
Storage, installation and operating instructions,
Documents
shipping list and spare parts list
Note: For non-standard options contact Nalco Global Equipment Solutions.

APPENDIX G
Equipment
Specifications
LI-Series

UltraSoft
DUPLEX
Water Softeners

UltraSoft LI-Series Duplex Alternating Softeners
Model NFZSD (Volume Initiated)
Two softener vessels are supplied with high capacity cation exchange resin and a
gravel support bed. The inlet diffuser evenly distributes influent water, collects
backwash water and introduces the brine regenerant solution. The lower hub and
lateral or single point distributor (depending upon tank size) collects effluent and
regeneration water as well as distributes the backwash water.
the operational steps of backwash, brining, slow rinse, fast rinse and refill cycles. The
brass control valve includes fixed and self-adjusting flow regulators to control flow rates
during each operational cycle. The valve seals are static o-rings and separated by
precision positioned spacers. The cycles of regeneration are accomplished with the
movement of a hydraulically balanced Teflon coated piston. The piston is the only
moving part in the main control valve.

The dual tank configuration provides softened water during service. The system does
not have an internal by-pass valve, thus preventing raw water bypass during the
regeneration cycle. The system consists of two control valves, two mineral tanks, one
brine tank, one digital totalizing meter, resin and a gravel support bed.
A digital totalizing water meter initiates regeneration. The operator can manually initiate
regeneration at any time.
These softeners operate in an alternating fashion. Only one softener will be in the
service mode or regeneration mode at any given time. When the preset volume of
water has been treated, the first softener will begin the regeneration mode and the
second softener will begin the service mode. The digital totalizing water meter is reset
to zero when each softener begins its regeneration mode.

Maximum Reference
Model Number Flow Rate (Kgrains-Pipe
(gpm) Size)
NFZSD009FPZVAX 19 30-1
NFZSD012FPZVBX 39 60-1.5
NFZSD018FPZVCX 81 150-2
NFZSD030FPZVEX 213 450-3

NFZSD048FPZVEX 275 1,200-3
Model Number: NFZSD 021 F P Z V B X
Vessel Size
009 9 x 40
012 12 x 52
014 14 x 65
016 16 x 65
018 18 x 65
021 21 x 62
024 24 x 72
030 30 x 72
036 36 x 72
042 42 x72
048 48 x 72
Vessel Design
F Non-Code
Controls
P NEMA
3R
Assembly
Z Free standing
Regeneration
V Digital alternating, meter initiated
Inlet / Outlet Size

A Available on 9 through 16 diameter
1
units
B Available on 12 through 24 diameter
1
units
E Available on 30 through 48 diameter
3
units
Options
X No options

Design Parameters:
Configuration Duplex Alternating
Freeboard 53% minimum
Pressure Vessels
Rating 150 psig
Access Openings
Lower (underdrain)
10 diameter through 18
PVC basket strainer
diameter w/ 1 pipe
18 diameter w/1 pipe Single row PVC hub and Schedule 80 PVC
through 36 slotted radials
Top Mount Valve
Rating 125 psig
Enclosure NEMA 3
Controller and Totalizing Meter Fleck model 3200 NT

None

Operating Limits:
Temperature
Pressure

Parameter Limit
Chlorine 0.5 ppm

Electrical NEMA 3
Documents

APPENDIX H
FLECK SERVICE
MANUAL
2750 Manual(R2).pdf

APPENDIX I
FLECK SERVICE
MANUAL
2850 Manual(R5).pdf

APPENDIX J
FLECK SERVICE
MANUAL
2900 Manual(R4).pdf

APPENDIX K
FLECK SERVICE
MANUAL
3900 Manual(R2).pdf

APPENDIX L
FLECK SERVICE
MANUAL
9000-9500 Manual
(A).pdf

APPENDIX M
FLECK SERVICE
MANUAL
3200 NT Service
Manual 41093-B(02-
04).pdf

APPENDIX N
FLECK SERVICE
MANUAL
3200 NT Master
Programming
41096-B.pdf

NOTES:

NOTES:

NOTES:


LI-Series Install-Operation Manual Ver1 - 0 For Sept 07 SRVC

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ULTRATREAT LI-SERIES

Installation and Operation Manual

This manual covers

UltraSoft LI-Series Water Softeners

THIS MANUAL BELONGS TO:

Need Technical Help? PAGE 2 of 166

Table of Contents Page

1.1 About ULTRATREAT Service ................................................ 7

Section 2: Technology Overview

2.2 The Filtration Process........................................................... 22

2.3 The Softening Process.......................................................... 24

2.4 Principles of Ion Exchange Resin ........................................ 27

Need Technical Help? PAGE 3 of 166

Section 2: Technology Overview continued

2.5 The Filtration Operating Sequence ...................................... 33

2.6 The Softener Operating Sequence ....................................... 36

Section 3: Installation and Start-Up

3.2 STEP 2 PRE-INSTALLATION CHECK-LIST ....................... 44

Need Technical Help? PAGE 4 of 166

Section 3: Installation and Start-Up continued

3.4 STEP 4 LOCATING ............................................................. 55

3.5 STEP 5 VALVE & PIPING INSTALLATION......................... 57

3.6 STEP 6 MEDIA LOADING ................................................... 90

3.7 STEP 7 INSTALLATION CHECKLIST................................. 94

Need Technical Help? PAGE 5 of 166

Section 3: Installation and Start-Up continued

Need Technical Help? PAGE 6 of 166

1.1 About ULTRATREAT Service

The Nalco equipment product offering is heavily weighted towards chemical

1.2 About this Manual

! Additional help is available at NGES HELP DESK 630-848-3387

Need Technical Help? PAGE 7 of 166

Section 2: Technology Overview

2.1.1 Water Impurities

Abundant supplies of fresh water are essential to the development of industry.

The Hydrologic Cycle

Evaporation under the influence of sunlight takes water from a liquid to a

Water: Universal Solvent

Pure water (H20) is colorless, tasteless, and odorless. It is composed of hydrogen

Need Technical Help? PAGE 8 of 166

Section 2: Technology Overview

2.1.1 Water Impurities continued

Water impurities include dissolved and suspended solids. Calcium bicarbonate is

Table 2.1.1.1: Common impurities found in fresh water.

Constituent Chemical Formula Difficulties Caused Means of Treatment

Free Mineral H2SO4 , HCI. etc.,

corrosion in water lines,

Need Technical Help? PAGE 9 of 166

Need Technical Help? PAGE 10 of 166

The physical and chemical characteristics of surface water contamination vary

Need Technical Help? PAGE 11 of 166

Section 2: Technology Overview

2.1.1 Water Impurities continued

Table 2.1.1.2: A comparison of surface water and groundwater characteristics.

Characteristic Surface Water Ground Water

In contrast to surface supplies, groundwaters are relatively free from suspended

Groundwater chemistry tends to be very stable over time. A groundwater may

Need Technical Help? PAGE 12 of 166

Section 2: Technology Overview

2.1.1 Water Impurities continued

As groundwater encounters different minerals, it dissolves them according to

A good example is the reaction of groundwater with limestone. Water percolating

The salt formed by the reaction is a mixture of calcium and magnesium