Corrosion Coupon Rack
INSTALLATION & OPERATION MANUAL
72-912-00 1 Revision C
Table of Contents
1 Cautions and Warnings .......................................................................................... 2
2 Temperature to Pressure Ratings ................................................................................. 3
3 Installation ......................................................................................................... 4
4 Operation ......................................................................................................... 5
5 Specifications .................................................................................................... 6
6 Parts ............................................................................................................... 7
7 Technical Support ............................................................................................... 7
1 Cautions and Warnings
1. It is recommended that the installer and operator utilize the appropriate personal safety equipment while
interacting with the Corrosion Coupon Rack (CCR); i.e. safety glasses, gloves, etc.
2. It is the installer’s responsibility to install the product away from sensitive equipment such as open electrical
devices to protect from potential electrical shock and or damage in the event of a leak or failure of the CCR
assembly.
3. It is the installer’s responsibility to provide for secondary containment, leak detecting equipment and or
drainage of potential water that may drip from the CCR during normal usage or in the unlikely event of a
rupture/failure.
4. This device has a rated operating pressure; however rapid pressure spikes that result from water hammer or
uncontrolled surges from external sources can cause pressures far above the rating of the product. The
purchaser/installer must make sure these spikes are prevented to assure safe operation of the CCR.
5. PVC versions of the CCR can be affected by high temperatures. The device is not designed to operate above
140O F (60O C). Pressure is also derated at higher temperatures.
6. Any modification to the CCR voids the warranty and any resulting failure is the sole responsibility of the
purchaser/installer.
7. Removal of the CCR piping from the supplied back plate is a modification not allowed and voids the warranty.
8. Prior to any service to the unit, always close the inlet isolation valve and release the pressure and completely
drain the unit.
72-912-00 2 Revision C
PVC Temperature to Pressure Ratings
PVC Schedule 80 Industrial Pipe
Operating
Temp (°F)
Operating
Temp (°C)
% Pressure
Derate
Nom. Size
(in)
Maximum
Working
Pressure (PSI)
73
22.8
100%
1/2"
850
80
26.7
88%
3/4"
690
90
32.2
75%
1"
630
100
37.8
62%
110
43.3
51%
120
48.9
40%
130
54.4
31%
140
60.0
22%
CPVC Temperature to Pressure Ratings
CPVC Schedule 80 Industrial Pipe
Operating
Temp (°F)
Operating
Temp (°C)
De-Rating
Factor
Nom. Pipe
Size (in)
Maximum
Working
Pressure (PSI)
80
26.7
100%
1/2"
850
90
32.2
91%
3/4"
690
100
37.8
82%
1"
630
110
43.3
72%
120
48.9
65%
130
54.4
57%
140
60.0
50%
150
65.6
42%
160
71.1
40%
170
76.7
29%
180
82.2
25%
200
93.3
20%
Example:
Material Type
Pipe Size
Temperature
Max W.P.
De-Rating Factor
De-Rated Max
W.P.
CPVC
1/2"
120 °F
850 x 65% =
552.5
2 Temperature to Pressure Ratings
72-912-00 3 Revision C
Corrosion Coupon Rack
3 Installation
Corrosion coupon racks are typically installed on the side stream of re-circulating systems to allow for
controlled testing of coupon samples. Samples are periodically removed and examined by a laboratory in
order to calculate corrosion rates and other effects such as pitting.
1) Securely fasten the coupon rack to a wall or other rigid surface.
2) Secure inlet and outlet piping using a suitable pipe clamp.
3) The coupon rack is designed with the inlet on the bottom and the outlet at the top, there must be more
pressure on the inlet side than there is on the outlet side in order for flow to occur.
4) Do not install any ancillary equipment on the inlet side of the sample stream, e.g, metering pumps,
sensors or analyzers.
5) Avoid installations that have variable flow velocities; installation of a flow control valve may be required.
6) Install inlet and outlet isolation valves (unless equipped).
The corrosion coupon rack is designed for outdoor installations, PVC and CPVC models should not be
exposed to direct sunlight and must be protected from environmental conditions. Verify that the pressure and
temperature of the installation do not exceed those in the specifications section of this manual.
72-912-00 4 Revision C
COUPON
MOUNTING
HARDWARE
SUPPLIED
WITNESS
SLOT
WITNESS
TABS
4 Operation
To remove the coupons, turn off the isolation valves and loosen the coupon holder to remove the coupon
sample. Install the coupon by hand tightening the holder into the tee, noting the witness marks on the holder
body. Restore flow by opening the isolation valves and then inspect for leaks.
Threaded Connect Style
Quick Release Style
Coupon Handling:
Do not leave finger prints on samples.
Do not clean samples.
Use the treated envelope supplied with coupon samples for storage before and after testing.
Use TFE tape on threaded type holders, quick connect type holders use O-Ring style seals.
Witness slot (or tabs) on holders must be vertical so that the coupon is also vertical.
72-912-00 5 Revision C
5 Specifications
3/4" PVC piping
1" PVC piping
3/4" CPVC piping
1" CPVC piping
3/4" black iron
piping
max 150 psi (10.4
bar), 1400 F (600C)
max 150 psi (10.4
bar), 1400 F (600C)
max 150 psi (10.4
bar), 2120 F
(1000C)
max 150 psi (10.4
bar), 2120 F (1000C)
max 250 psi (10.4
bar), 2120 F (1000C)
Model
Model
Model
Model
Model
Model
Model
Model
Model
Model
CCR1
CCR10
CCR1A
CCR10A
CCR1B
CCR10B
CCR10C
CCR10C
CCR1D
CCR10D
CCR2
CCR20
CCR2A
CCR20A
CCR2B
CCR20B
CCR20C
CCR20C
CCR2D
CCR20D
CCR3
CCR30
CCR3A
CCR30A
CCR3B
CCR30B
CCR30C
CCR30C
CCR3D
CCR30D
CCR4
CCR40
CCR4A
CCR40A
CCR4B
CCR40B
CCR40C
CCR40C
CCR4D
CCR40D
CCR5
CCR50
CCR5A
CCR50A
CCR5B
CCR50B
CCR50C
CCR50C
CCR5D
CCR50D
CCR6
CCR60
CCR6A
CCR60A
CCR6B
CCR60B
CCR60C
CCR60C
CCR6D
CCR60D
Available options:
Option
Description
X1
Quick release coupon holders (PVC only)
X4
3/4 hot/cold water flow meter 150 psi (10.4 bar) max 130ºF (54ºC). max
X6
1 cold water flow meter 150 psi (10.4 bar) max 130ºF (54ºC) max
X7
PVC outlet ball valve std, 3/4 blk iron units use 3/4" brass ball valve
X8A
Y Strainer for 3/4 PVC
X8B
Y Strainer for 1 PVC or CPVC
X8C
Y Strainer for 3/4 CPVC or black iron
X8D
3/4" Polypropylene bowl strainer 30 mesh, 150 psi max 70⁰F max
X8E
1" Polypropylene T strainer 30 mesh, 150 psi max 70⁰F max
X9
Clear PVC pipe sections
F3
Flow control valve 3 GPM (3/4" only)
F5
Flow control valve 5 GPM (3/4" only)
Z4
Sample and Drain port
1F10
1" 10 GPM Flow control Valve
1F5
1" 5 GPM Flow control Valve
72-912-00 6 Revision C
Coupon Rack Replacement Parts
Part No.
Description
16-756-51-1
Quick Release coupon holder with hardware
16-756-50
PVC and CPVC holder with hardware
16-756-42
Steel on black iron holder with hardware
16-756-43
Steel on black iron holder with hardware
High Temp / Pressure
33-022-16
3/4 hot/cold water flow meter
6 Parts
7 Technical Support
Factory Service Policy
If you are experiencing a problem with your corrosion coupon rack, first consult the troubleshooting guide in this
manual. If the problem is not covered or cannot be solved, contact Technical Services for assistance:
PULSAFEEDER INC. (SPO)
27101 AIRPORT ROAD
PUNTA GORDA, FL 33982
941-575-3800
Trained technicians are available to diagnose your problem and arrange a solution. Solutions may include purchase of
replacement parts or returning the unit to the factory for inspection and repair. All returns require a Return
Authorization number to be issued by Pulsafeeder. Parts purchased to correct a warranty issue may be credited after
an examination of original parts by Pulsafeeder. Warranty parts returned as defective which test good will be sent back
freight collect. No credit will be issued on any replacement electronic parts.
Any modifications or out-of-warranty repairs will be subject to bench fees and costs associated with replacement parts.
Warranty
Pulsafeeder, Inc. warrants control systems of its manufacture to be free of defects in material or workmanship. Liability
under this policy extends for 12 months from date of shipment. Electrodes/probes are considered maintenance items
and as such are warranted for six (6) months from the date of shipment of the controller. Electrodes/probes purchased
as spare parts are warranted for 90 days from date of shipment. The manufacturer's liability is limited to repair or
replacement of any failed equipment or part, which is proven defective in material or workmanship upon completion of
the manufacturer's examination. This warranty does not include removal or installation costs and in no event shall the
manufacturer's liability exceed the selling price of such equipment or part.
The manufacturer disclaims all liability for damage to its products through improper installation, maintenance, use, or
attempts to operate such products beyond their functional capacity, intentionally or otherwise, or any unauthorized
repair. The manufacturer is not responsible for consequential or other damages, injuries, or expense incurred through
the use of its products.
The above warranty is in lieu of any other warranty, whether expressed or implied. The manufacturer makes no
warranty of fitness or merchantability. No agent of ours is authorized to provide any warranty other than the above.
72-912-00 7 Revision C
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