De Nora Capital Controls 1041B Series Instruction Manual

Instruction Manual ­Series 1041B

CAPITAL CONTROLS

®

- 1 - 310.6002.0

These instructions describe the installation, operation and maintenance of the subject equipment. Failure to strictly follow
these instructions can lead to an equipment rupture that may cause signicant property damage, severe personal injury and
even death. If you do not understand these instructions, please call De Nora Water Technologies (DNWT), Inc. for clarication
before commencing any work at [phone] and ask for a Field Service Manager. De Nora Water Technologies, Inc.
reserves the rights to make engineering renements that may not be described herein. It is the responsibility of the installer
to contact DNWT Inc. for information that cannot be answered specically by these instructions.

Any customer request to alter or reduce the design safeguards incorporated into DNWT Inc. equipment is conditioned
on the customer absolving DNWT Inc. from any consequences of such a decision.

DNWT Inc. has developed the recommended installation, operating and maintenance procedures with careful attention to
safety. In addition to instruction/operating manuals, all instructions given on labels or attached tags should be followed.
Regardless of these eorts, it is not possible to eliminate all hazards from the equipment or foresee every possible hazard
that may occur. It is the responsibility of the installer to ensure that the recommended installation instructions are followed.
It is the responsibility of the user to ensure that the recommended operating and maintenance instructions are followed.
De Nora Water Technologies, Inc. cannot be responsible for deviations from the recommended instructions that may result in
a hazardous or unsafe condition.

DNWT Inc. cannot be responsible for the overall system design of which our equipment may be an integral part of or any
unauthorized modications to the equipment made by any party other than DNWT Inc.

DNWT Inc. takes all reasonable precautions in packaging the equipment to prevent shipping damage. Carefully inspect each
item and report damages immediately to the shipping agent involved for equipment shipped “F.O.B. Colmar” or to DNWT Inc.
for equipment shipped “F.O.B Jobsite”. Do not install damaged equipment.

De Nora Water Technologies Inc., COLMAR OPERATIONS
COLMAR, PENNSYLVANIA, USA
is ISO 9001: 2008 CERTIFIED

310.6002.0 - 2 -

Table of Contents

1 INTRODUCTION .......................................................................................... 4

1.1 General ......................................................................................................4

1.2 Specications ................................................................................................4

1.3 Automatic Switchover System Components ...................................................................4

1.4 Principle of Operation ........................................................................................4

2 INSTALLATION ........................................................................................... 8

2.1 Automatic Switchover Electronics ............................................................................8

2.2 Motorized Ball Valves Mounting ..............................................................................8

2.3 Pressure Switches ............................................................................................8

2.4 Electrical Connections ........................................................................................8

3 START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1 General ......................................................................................................9

3.2 Leak Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

4 OPERATION ............................................................................................. 11

4.1 General .....................................................................................................11

4.2 Indicators ...................................................................................................11

4.2.1 Automatic Mode .....................................................................................11

4.2.2 Manual Override Mode ...............................................................................13

4.2.3 Empty Indications ....................................................................................13

4.2.4 Closed Indications ....................................................................................13

4.2.5 Emergency Shutdown/Failure Indications .............................................................14

5 SERVICE ................................................................................................15

5.1 Automatic Switchover ......................................................................................15

5.2 System Shutdown for Routine Maintenance ..................................................................15

5.3 Expansion Chamber Rupture Disc Replacement (Liquid System Only) .........................................16

5.4 PLC Reset Instructions .......................................................................................16

5.5 PLC Fault (Blinking Red Light) ................................................................................16

6 TROUBLESHOOTING CHART .............................................................................17

FIGURES

1 Automatic Switchover Unit Faceplate .........................................................................5

2 Automatic Switchover System - Gas Withdrawal ...............................................................6

3 Automatic Switchover System - Liquid Withdrawal ............................................................7

4 Programmable Controller Indicators ..........................................................................9

- 3 - 310.6002.0

1 INTRODUCTION

1.1 General

These instructions apply to the Series 1041 and 1041B Automatic Switchover control units. Instruction manuals for
other system components and supplemental data are referenced where applicable.

The Series 1041 Automatic Switchover model number describes the basic design as follows:

MODEL 1 0 4 1 (B)

Design/Inspection
01 - Standard
02 - Special Requirements

Power Requirements
01 - 120 Vac, 50/60 Hz, single phase
02 - 240 Vac, 50/60 Hz, single phase

1.2 Specications

Operation: Automatic switchover with manual override

Control: Programmable logic controller

Field Inputs: 24 Vdc source supplied

Field Outputs: 5/10 amps at 120 Vac, resistive load

Control Selector Switches: Mode (Auto/Manual), Side A (Open/Closed), Side B (Open/Closed), Reset

Control Panel Design: Graphic mimic panel

Control Indicators: Steady state or ashing indicators (Empty, Open, Closed, Stand-by) for Side A and Side B

Flashing Indicators: Valve action, operator error, switchover malfunction, remote shutdown

Failure Alarms: Field congurable

Safety Features: Safety interlocks, latching alarm circuit with manual reset, automatic remote shutdown

Power Requirements: 120 Vac or 240 Vac, 50/60 Hz, single phase

Shipping Weight: 45 lbs (20 kgs)

Enclosure: NEMA 4X

Switches: NEMA 4X, industrial grade

Mounting: Wall

1.3 Automatic Switchover System Components - See Figures 1, 2 and 3

The Series 1041 Automatic Switchover System consists of the automatic switchover electronics unit with
programmable logic controller, a pressure switch and a motorized ball valve for each source, liquid expansion
chambers with rupture discs to protect liquid pipelines from hydrostatic rupture if liquid is switched, and optional
manifolds and manifold bypass valves when gas is switched. Pressure switches, motorized ball valves, expansions
chambers and manifolds are specic to the gas or liquid being dispensed.

1.4 Principle of Operation

The Series 1041B Automatic Switchover System provides for automatic switching with manual override between two
independent sources of liquid or gas chemical assuring an uninterrupted supply of chemical to liquid vaporizing or
gas feed equipment.

The automatic switchover system is suitable for pressure or vacuum operation.

310.6002.0 - 4 -

Automatic switchover is initiated by low pressure (high vacuum) of the on-line source and resulting switch closure.
The mechanical limit switch in each motorized ball valve actuator is adjusted to transfer when the valve reaches the
closed position. When the controller senses a limit switch closure, it opens the motorized ball valve on the stand-by
source. The automatic switchover design uses the mechanical limit switches to prevent either motorized ball valve
from opening before the other motorized ball valve is completely closed.

Manual override is accomplished by selecting the manual mode using the Auto/Manual selector switch, then
manually opening or closing the desired valve using the Side A or Side B, Open/Closed selector switches.

Manual

Auto

Close

Open

Close

Open

W

Off

On

W

G AR

AGR

Reset

Figure 1 - Series 1041B Automatic Switchover Unit Faceplate

- 5 - 310.6002.0

NOTE: Gas supply may be cylinders, ton container or a combination of both. All containers in use must be at the same

PS PS

ALARM CONTACTS
SIDE A / SIDE B

OPEN / CLOSED

REMOTE STATUS CONTACT

VALVE A, VALVE B

VALVE A VALVE B

SIDE A SIDE B

Auto

Open

Manual

Open

Close

Close

Reset

SYSTEM

DISPENSING

GAS TO

On

Off

temperature.

Gas Service Components:
Automatic switchover controller (120 Vac or 240 Vac)

3/4" Manual valve
3/4" Valve with motorized operator
Pressure switch with diaphragm protector (Range: 5-30 psig)

NOTE: Manifolds are required for cylinder or ton container withdrawal.

Figure 2 - Automatic Switchover System - Gas Withdrawal

310.6002.0 - 6 -