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User Manual
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USFilter V-2000 User Manual

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Page 1
SERIES V-2000
CHLORINATOR
3000 LB/24 HR
AUTOMATIC CONTROL
BOOK NO. IM 25.055AC UA ISSUE C
Page 2
IM 25.055AC UA (C/6-01)
EQUIPMENT SERIAL NO. _________________ DATE OF START-UP _____________________ START-UP BY ___________________________ Prompt service available from nationwide authorized service contractors.
ORDERING INFORMA TION
In order for us to fill your order immediately and correctly, please order material by description and part number , as shown in this book. Also, please specify the serial number of the equipment on which the parts will be installed.
WARRANTY
Seller warrants for a period of one year after shipment that the equipment or material of its manufacture is free from defects in workmanship and materials. Corrosion or other decomposition by chemical action is specifically excluded as a defect covered hereunder, except this exclusion shall not apply to chlorination equipment. Seller does not warrant (a) damage caused by use of the items for purposes other than those for which they were designed, (b) damage caused by unauthorized attachments or modifications, (c) products subject to any abuse, misuse, negligence or accident, (d) products where parts not made, supplied, or approved by Seller are used and in the sole judgement of the Seller such use affects the products’ performance, stability or reliability , and (e) products that have been altered or repaired in a manner in which, in the sole judgement of Seller, af fects the products’ performance, stability or reliability. SELLER MAKES NO OTHER WARRANTY OF ANY KIND, AND THE FOREGO-
ING WARRANTY IS IN LIEU OF ALL OTHER W ARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY W ARRANTY OF MERCHANTABILITY OR OF FITNESS OF THE MATERIAL OR EQUIPMENT FOR ANY PARTICULAR PURPOSE EVEN IF THA T PURPOSE IS KNOWN TO SELLER. If Buyer discovers a defect in material or workmanship, it must promptly notify
Seller in writing; Seller reserves the right to require the return of such defective parts to Seller, transportation charges prepaid, to verify such defect before this warranty is applicable. In no event shall such notification be received by Seller later than 13 months after the date of shipment. No action for breach of warranty shall be brought more than 15 months after the date of shipment of the equipment or material.
LIMITATION OF BUYER’S REMEDIES. The EXCLUSIVE REMEDY for any breach of warranty is the replacement f.o.b. shipping point of the defective part or parts of the material or equipment. Any equipment or material repaired or replaced under warranty shall carry the balance of the original warranty period, or a minimum of three months. Seller shall not be liable for any liquidated, special, incidental or consequential damages, including without limitation, loss of profits, loss of savings or revenue, loss of use of the material or equipment or any associated material or equipment, the cost of substitute material or equipment, claims of third parties, damage to property, or goodwill, whether based upon breach of warranty , breach of contract, negligence, strict tort, or any other legal theory; provided, however, that such limitation shall not apply to claims for personal injury .
Statements and instructions set forth herein are based upon the best information and practices known to U.S. Filter/Wallace & Tiernan, Inc., but it should not be assumed that every acceptable safety procedure is contained herein. Of necessity this company cannot guarantee that actions in accordance with such statements and instructions will result in the complete elimina­tion of hazards and it assumes no liability for accidents that may occur.
1.010-42D
WALLACE & TIERNAN PRODUCTS
1901 West Garden Road, Vineland, NJ 08360
Page 3
IM 25.055AC UA (C/6-01)
AUTOMATIC CHLORINA TOR - 3000LB/24HR
INTRODUCTION
This instruction book provides installation, operation, and maintenance instructions for the USFilter's Wallace & Tiernan Products (USF/W&T) Series V-2000 (Chlorine) Gas Feeder (control module and injector). Of necessity, more information is provided than applies to each specific instal­lation; disregard those details that do not apply to your installation.
Instructions for accessory equipment, where applicable, are provided in separate books included with that equipment.
The complete gas feeder consists of a control module, an injector, and a vacuum regulator. The vacuum regulator is covered by a separate instruc­tion book provided with that equipment.
WARNING: DO NOT USE THIS EQUIPMENT FOR SWIMMING POOL, WATER PARK, OR SIMILAR RECREATIONAL APPLI­CATIONS. IT IS NOT SOLD FOR SUCH USE.
The USF/W&T Gas Feeder is designed to meter and control the flow of chlorine gas. An injector accepts this flow of gas, mixes it with water, and delivers the resultant solution to the point of application. By using a selec­tion of rotameters and valve seats, the gas feeder may be adapted to meet a wide range of capacity requirements. Thus, as requirements change over a period of time, the capacity of the gas feeder may be changed accordingly. A large indicator scale on the rotameter permits a direct reading of the rate of gas feed in pounds per 24 hours. Control of the feed rate is electric; however, a simple release mechanism permits the operator to assume manual control at any time. The gas feeder is normally equipped with a two-inch variable throat injector.
WARNING: HAZARDOUS GAS IS PRESENT IN THIS EQUIP­MENT DURING NORMAL OPERATION. TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR DAMAGE TO THE EQUIP­MENT, READ THIS INSTRUCTION BOOK AND THE APPRO­PRIATE GAS MANUAL BEFORE CONNECTING THIS EQUIP­MENT TO A SUPPLY OF GAS. OPERATION AND MAINTE­NANCE OF THIS EQUIPMENT MUST BE RESTRICTED TO TRAINED, QUALIFIED PERSONNEL WHO ARE COMPLETELY FAMILIAR WITH THESE INSTRUCTIONS. CONSULT FAC­TORY FOR APPLICATIONS AGAINST A NEGATIVE HEAD (PARTIAL VACUUM) OR A POSITIVE BACKPRESSURE OF LESS THAN 1.0 PSI (28 INCHES OF WATER) IN THE SOLUTION DISCHARGE LINE.
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Introd.
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IM 25.055AC UA (C/6-01)
NOTE: When ordering material always specify model and serial number of apparatus.
Table Of Contents
Very Important Safety Precautions........................... 1.010-40,-41
Preventive Maintenance General Information........... 1.010-5
Maintenance Record Card ........................................ 1.010-13
Regional Offices........................................................ 1.010-1
Technical Data .......................................................... Section 1
Installation................................................................. Section 2
Operation .................................................................. Section 3
Service ...................................................................... Section 4
Illustrations ............................................................... Section 5
Preventive Maintenance Kits and Spare Parts List ... Section 6
Literature/Manuals.................................................... Section 7
Chlorine Handling Manual ..................................... IM 25.000AA
Introd. (Cont'd)
Page 5
IM 25.055AC UA (C/6-01)
AUTOMATIC CHLORINA TOR - 3000LB/24HR
VERY IMPORTANT SAFETY PRECAUTIONS - CHLORINE
This and the following pages titled “V ery Important Safety Precautions” provide, in brief, information of urgent importance relative to safety in the installation, operation, and maintenance of this equipment.
WARNING
TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE, OBSERVE THE FOLLOWING:
THIS EQUIPMENT SHOULD BE INST ALLED, OPERA TED, AND SERVICE ONL Y BY TRAINED, QUALIFIED PERSONNEL WHO ARE THOROUGHLY FAMILIAR WITH THE ENTIRE CON­TENTS OF THIS INSTRUCTION BOOK AND THE CHLORINE GAS HANDLING MANUAL.
CHLORINE GAS IS A RESPIRATORY IRRITANT. EXPOSURE TO CHLORINE GAS IN SUFFI­CIENT CONCENTRATION PRODUCES IRRITATION OF THE MUCOUS MEMBRANES, THE RESPIRA T ORY SYSTEM, AND THE SKIN. IN EXTREME CASES, SUFFOCATION AND DEATH CAN OCCUR.
WHEN CHANGING CHLORINE CYLINDERS, IT IS RECOMMENDED PRACTICE TO HAVE AN APPROVED GAS MASK AVAILABLE THAT YOU HAVE BEEN TRAINED TO USE AND YOU MUCH BE COMPLETELY FAMILIAR WITH YOUR LOCAL PLANT OPERATING AND EMERGENCY PROCEDURES AND CHLORINE INSTITUTE RECOMMENDED EMERGENCY PROCEDURES.
DO NOT TOLERATE ANY CHLORINE LEAKS. CHLORINE LEAKS NEVER GET BETTER. CHLORINE LEAKS AL WAYS GET PROGRESSIVELY WORSE IF THEY ARE NOT PROMPTL Y CORRECTED. IT IS RECOMMENDED PRACTICE TO HAVE AN APPROVED GAS MASK A VAIL­ABLE WHEN MAKING LEAK CHECKS.
AS SOON AS THERE IS ANY INDICATION OF CHLORINE IN THE AIR, TAKE IMMEDIATE STEPS TO CORRECT THE CONDITION.
IMPORTANT INFORMATION RELATED TO SAFETY OF CHLORINATION EQUIPMENT IN­ST ALLATION IS PROVIDED IN THE CHLORINE GAS HANDLING MANUAL. IN THE INTER­EST OF SAFE OPERATION, THIS INFORMATION MUST BE READ, UNDERSTOOD, AND PRACTICED BY EQUIPMENT OPERATORS AND THEIR SUPERVISORS.
AT TIME OF INITIAL INSTALLATION, WHEN CHLORINE SUPPLY LINES HAVE BEEN DIS­CONNECTED FOR ANY REASON AND ON A ROUTINE DAIL Y BASIS, THOROUGHL Y CHECK ALL JOINTS, CONNECTIONS, AND EQUIPMENT FOR POSSIBLE CHLORINE LEAKS AND IMMEDIATELY CORRECT ANY THAT MA Y BE FOUND.
1.010-40
Page 6
IM 25.055AC UA (C/6-01)
VERY IMPORTANT SAFETY PRECAUTIONS - CHLORINE (CONT’D)
WHEN ANY CONNECTION IS BROKEN EVEN FOR A SHORT TIME, IMMEDIATELY PLUG THE RESULTANT OPENINGS WITH A RUBBER STOPPER OR EQUIVALENT TO PREVENT THE ENTRANCE OF MOISTURE. MOISTURE MUST BE EXCLUDED FROM ANY PART OF THE EQUIPMENT THAT IS NORMALLY EXPOSED TO DRY CHLORINE ONLY. WHILE DRY CHLORINE IS NON-CORROSIVE, MOIST CHLORINE IS EXTREMEL Y CORROSIVE T O COM­MON METALS, SUCH AS BRASS OR STEEL.
THE TWO MOST COMMON CAUSES OF CHLORINE PIPING LEAKS ARE:
1. RE-USE OF GASKETS. THIS SHOULD NEVER BE DONE. ALWAYS HAVE AN AD­EQUA TE SUPPLY ON HAND AND ALWA YS USE NEW GASKETS OF THE CORRECT MATERIAL AND SIZE AS IDENTIFIED ON THE EQUIPMENT P ARTS DRA WING.
2. IMPROPERLY MADE-UP THREADED PIPE JOINTS. SEE CHLORINE GAS HAN­DLING MANUAL FOR RECOMMENDED PROCEDURE.
EXCEPT IN CASES OF LEAK DETECTION OR CALIBRATION ADJUSTMENTS, THE CHLO­RINE GAS SUPPL Y MUST BE SHUT OFF AT THE GAS SUPPL Y CONT AINERS AND THE CHLO­RINE GAS IN THE SYSTEM EXHAUSTED BEFORE SERVICING THE EQUIPMENT.
USE ONLY USF/W&T LISTED PARTS, EXCEPT FOR COMMERCIALLY AVAILABLE PARTS AS IDENTIFIED ON THE P AR TS LIST . THE USE OF UNLISTED P AR TS CAN RESUL T IN EQUIP­MENT MALFUNCTIONS HAVE HAZARDOUS CONSEQUENCES.
DO NOT DISCARD THIS INSTRUCTION BOOK UPON COMPLETION OF INSTALLATION. INFORMA TION PROVIDED IS ESSENTIAL T O PROPER AND SAFE OPERATION AND MAIN­TENANCE.
ADDITIONAL OR REPLACEMENT COPIES OF THIS BOOK ARE AVAILABLE FROM:
USFILTER'S W ALLACE & TIERNAN PRODUCTS 1901 WEST GARDEN ROAD VINELAND, NEW JERSEY 08360 PHONE: (856) 507-9000 FAX: (856) 507-4125
NOTE
Minor part number changes may be incorporated into USF/W&T products from time to time that are not immediately reflected in the instruction book. If such a change has apparently been made in your equipment and does not appear to be reflected in your instruction book, contact your local USF/W&T sales representative for information.
Please include the equipment serial number in all correspondence. It is essential for effective communi­cation and proper equipment identification.
1.010-41
Page 7
IM 25.055AC UA (C/6-01)
AUTOMATIC CHLORINA TOR - 3000LB/24HR
PROTECT YOUR EQUIPMENT INVESTMENT
MINIMIZE DOWNTIME
ORDER A PREVENTIVE MAINTENANCE KIT NOW ... KEEP ONE ON HAND
Quality + Preventive = Dependable Operation Equipment Maintenance Minimum Downtime
There’ s no question about it.
Equipment that is properly maintained is dependable equipment.
It will give optimum performance with minimum unscheduled downtime.
USFilter’s Wallace & Tiernan Products manufactures quality equipment designed for perfor­mance and reliability . Each product is carefully tested and inspected before shipment to ensure that it
meets our high standards.
Our equipment is engineered for easy maintenance. To ensure maximum service life and minimize unscheduled repairs, we recommend a program of regular preventive maintenance, as described in the Service section of this book. T o support this program, we developed. standard parts kits. These kits can also be used for minor emergency repairs to minimize downtime.
We r ecommend that these kits be available in your stock at all times. When the complete kit or any of its parts are used, the kit should be replaced immediately .
Preventive maintenance kits may be ordered directly fr om the company that supplied your equip­ment, or they may be ordered directly from USFilter’ s W allace & T iernan Products. For ordering
numbers, refer to the parts list at the rear of this book.
1.010-5E
Page 8
IM 25.055AC UA (C/6-01)
PREVENTIVE MAINTENANCE SCHEDULE
AND RECORD OF PERFORMANCE
This equipment should receive preventive maintenance on a one (1) year cycle.* It is recommended
that the following table be used to plan, schedule, and record this important work.
*NOTE: This is the recommended cycle. Your local operating conditions may call
for more frequent preventive maintenance.
1.010-13B
noitallatsnIfoetaD
goLecnanetniaMevitneverP
etaDeludehcS demrofrePetaD
PROTECT YOUR EQUIPMENT INVESTMENT
MINIMIZE DOWNTIME
ORDER A PREVENTIVE MAINTENANCE KIT NOW ... KEEP ONE ON HAND
Page 9
IM 25.055AC UA (C/6-01)
AUTOMATIC CHLORINA TOR - 3000LB/24HR
REGIONAL OFFICES
INST ALLATION, OPERATION, MAINTENANCE, AND SERVICE INFORMATION
Direct any questions concerning this equipment that are not answered in the instruction book to the Reseller from whom the equipment was purchased. If the equipment was purchased directly from USFilter's W allace & T iernan Products (USF/W&T), contact the of fice indicated below.
UNITED ST ATES
1901 West Garden Road V ineland, NJ 08360 TEL: (856) 507-9000 FAX: (856) 507-4125
CANADA
If the equipment was purchased directly from USF/W&T Canada, contact the nearest office indicated below.
ONTARIO QUEBEC
250 Royal Crest Court 243 Blvd. Brien Markham, Ontario Bureau 210 L3R3S1 Repentigny , Quebec (905) 944-2800 (514) 582-4266
MEXICO
If the equipment was purchased directly from USF/W&T de Mexico, contact the office indicated below .
V ia Jose Lopez Portillo 321 Col. Sta. Maria Cuautepec Tultitlan, Edo. de Mexico 54900 Mexico TEL: 525 879 0260 FAX: 525 875 2171
1.010-1D
Page 10
IM 25.055AC UA (C/6-01)
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IM 25.055AC UA (C/6-01)
1
SECTION 1 - TECHNICAL DATA
List Of Contents
PARA./DWG. NO.
Technical Data .......................................................... 1.1
Illustrations
Performance
V-2000 Injector Inlet Pressure Limits................. 25.055.190.010
Vacuum Line Length Limits ............................... 25.052.190.030
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IM 25.055AC UA (C/6-01)
2
1.1 Technical Data
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erusserPtelnIrotcejnImuminiMhcni-owtehtybderiuqersiisp02
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IM 25.055AC UA (C/6-01)
3
V-2000 INJECTOR INLET PRESSURE LIMITS
- PERFORMANCE
25.055.190.010
ISSUE 1 5-97
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IM 25.055AC UA (C/6-01)
4
VACUUM LINE LENGTH LIMITS - PERFORMANCE
Used In Remote Vacuum Gas Feeders
25.052.190.030
ISSUE 2 10-84
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IM 25.055AC UA (C/6-01)
5
SECTION 2 - INSTALLATION
List Of Contents
PARA./DWG. NO.
Location of Components........................................... 2.1
Gas Supply ................................................................ 2.2
Unpacking ................................................................. 2.3
Pressure Relief Valve ................................................ 2.4
Rotameter ................................................................. 2.5
Vent ......................................................................... 2.6
Electrical Connections .............................................. 2.7
Installation of Throat and Tailway ............................ 2.8
Injector Suction Connection ..................................... 2.9
Injector Water Supply............................................... 2.10
Drain ......................................................................... 2.11
Injector Discharge..................................................... 2.12
Point of Application .................................................. 2.13
Main Connection.................................................... 2.13.1
Open Well .............................................................. 2.13.2
Vacuum Regulator .................................................... 2.14
Leak Check ............................................................... 2.15
Injector Arrangements for Intermittent Start-Stop
Operation ............................................................... 2.16
Illustrations
Typical Installation
Series V-2000 Gas Feeder .................................. 25.055.110.035
Series V-2000 Gas Feeder - With 2" Injector..... 25.055.110.070
2" Injector With 3/4" Ball Valve......................... 25.055.110.075
Installation Piping
2" Injector - Connections for Prime and Flush
Operations........................................................ 25.100.006.122
2" Injector - Connections for Manual Suction
Shut-Off Unit ................................................... 25.100.06.131
2" Injector - Connections for Intermittent
Start-Stop Operation ........................................ 25.100.006.142
2" Injector - Connections for Intermittent
Start-Stop Operation With Injector Suction
Shut-Off Unit ................................................... 25.100.006.152
PVC Pipe - Installation .......................................... 50.830.110.011
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IM 25.055AC UA (C/6-01)
6
WARNING: THIS CONTROL MODULE IS DESIGNED TO OP­ERATE UNDER VACUUM ONLY. TO AVOID POSSIBLE SE­VERE PERSONAL INJURY OR EQUIPMENT DAMAGE, DO NOT CONNECT TO A SOURCE OF GAS UNDER PRESSURE.
2.1 Location of Components
The general physical requirements of the installation are shown on the Typical Installation drawings. Locate the control module so that the nec­essary gas and power supplies may be connected. Ready access to the equipment for operation, routine maintenance, and service is required. Locate the injector so that the water supply, solution line to the point of application, and suction lines are connected with access for service con­veniently provided.
2.2 Gas Supply
For gas supply installation details, refer to the separate instruction book provided with the vacuum regulator (which regulates the gas supply to the control module).
2.3 Unpacking
When the equipment and accessory items are unpacked, check all items against the packing list to be sure that no parts are discarded with the packing material. Whenever possible, unpack the equipment at the instal­lation site. Set aside items not required at the time of installation, such as spare parts, where they will be available when needed.
WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE, DO NOT DISCARD OR REMOVE THIS INSTRUCTION BOOK WHEN THE INSTALLATION IS COMPLETED. THE OPERATOR WILL NEED IT.
CAUTION: To prevent damage to the module, replace the shim washers underneath the module after the plywood feet are removed.
2.4 Pressure Relief Valve
WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE, A PRESSURE RELIEF VALVE MUST BE INSTALLED THE SYSTEM.
NOTE: See appropriate Typical Installation drawings.
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IM 25.055AC UA (C/6-01)
7
2.5 Rotameter
For protection in shipment, the rotameter and associated parts are re­moved after the gas feeder is factory tested. These parts are separately packaged; assemble and install as indicated on Dwg. 25.055.151.010.
2.6 Vent
As shown on the typical installation drawings, a vent line is required from the pressure relief port to a point outside the building where the gas cannot cause injury to personnel or damage to equipment. The proper installation of this line is important. For gases other than ammonia, the gradient of the line must be continuous (down, if possible), without traps, and the atmo­spheric end should point down and be screened against the entrance of foreign materials. For ammonia, the gradient of the line must be continuous (up, if possible), without traps, and the atmospheric end should point up and be provided with a suitable raincap to prevent the entrance of water and foreign materials. Allow for free discharge of vapor. Where traps are unavoidable, provisions for condensate removal must be installed at all low points. Suitable support for the vent is required throughout its entire length. The vent lines from the vacuum regulator-check units are covered in a separate book.
NOTE: See appropriate Typical Installation drawings at the end of this section.
WARNING: THE PRESSURE RELIEF VALVE MUST BE VENTED TO AN AREA WHERE GAS FUMES CANNOT CAUSE INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT. DO NOT TER­MINATE THE VENT LINE AT A LOCATION ROUTINELY USED BY PERSONNEL, SUCH AS WORK AREAS OR PATHWAYS, NOR NEAR WINDOWS OR VENTILATION SYSTEM INTAKES.
2.7 Electrical Connections
If the control module is furnished with built-in accessories requiring a power supply or wiring to other equipment, appropriate wiring diagrams will be found in the instructions for the accessory items.
NOTE: Field wiring must conform to local electrical codes.
2.8 Installation of Throat and Tailway
The throat and tailway of 3/4-inch and one-inch fixed throat injectors must be assembled as shown on the parts drawings. If faulty injector action is
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IM 25.055AC UA (C/6-01)
8
suspected, inspect the O-rings and replace them if there is any doubt about their condition.
2.9 Injector Suction Connection
Except in those instances where the injector is installed in the control module, a line must be provided to carry the gas from the module to the injector. The piping must be sized as required to obtain six inches of mercury minimum vacuum at the module.
2.10 Injector Water Supply
The injector requires a supply of reasonably clean water. Equip the water supply up to and including two-inch sizes with a strainer, as indicated in the Typical Installation drawing in this section. The pressure and quantity of water required varies from one installation to another.
2.11 Drain
Two-inch bellofram type injectors used for start-stop operation require a 1/4-inch ID drain hose to dispose of a short spurt of water when the injector is operated. Run the drain hose to a suitable floor drain or waste pipe.
For one-inch and 3/4-inch fixed throat injectors, no floor drain is required; however, a drain is always desirable to facilitate injector service.
2.12 Injector Discharge
For 3/4-inch fixed throat injector, the tailway (beige color) is designed to accept 3/4-inch polyethylene tubing or 3/4-inch threaded pipe connection.
NOTE: For pipe thread connection, do not cut off the serrated sec­tion.
For one-inch fixed throat injectors, a rigid PVC pipe or USF/W&T solu­tion hose is required between the injector discharge and the point of appli­cation. The pipe size depends on the size of the throat and tailway used in the injector, the operating water pressure, and length of the solution line. Solution hose may be connected directly to the injector tailway. If rigid PVC pipe is used, a piece of straight pipe at least eight inches long should be coupled to the end of the injector tailway before any elbows, tees, or Saunders valves are used. This is to prevent any flow disturbances that could affect the hydraulic performance of the tailway connections (see Dwg. 25.200.003.010).
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IM 25.055AC UA (C/6-01)
9
For the two-inch variable throat injectors, two-inch polyethylene pipe or two-inch rigid PVC pipe is normally used. Solution hose may be connected directly to the injector tailway. If rigid PVC pipe is used, a piece of straight pipe at least 12 inches long should be coupled to the end of the injector tailway before any elbows, tees, or Saunders valves are used. This is to prevent any flow disturbances that could affect the hydraulic performance of the tailway. Discharge in an upward direction.
2.13 Point of Application
2.13.1 Main Connection
If the solution is to be applied in a main, a suitable pipe tap is required in the main to accommodate the solution tube or diffuser.
2.13.2 Open Well
If the solution is to be applied in a basin, flume, channel, etc., where there is no pressure, the line from the injector must be supported so that the open end is submerged to the bottom of the chamber, or a minimum of six feet, if possible, and is located in a nonstagnant area.
2.14 V acuum Regulator
A vacuum regulator (or vacuum regulator-check unit), which is a gas pressure reducing valve (and check), is connected to the control module inlet. Refer to the separate instruction book supplied with the unit for installation instructions for the unit.
2.15 Leak Check
After the vacuum regulator(s) (or vacuum regulator-check unit) are in place, and before the gas tubing or piping that will connect it to the control module is installed, check for gas leaks as directed in the separate instruc­tion book provided with the vacuum regulator.
WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE, DO NOT TOLERATE ANY CHLO­RINE LEAKS. LEAKS ALWAYS GET PROGRESSIVELY WORSE AND MUST BE CORRECTED PROMPTLY.
NOTE: The vacuum line extending from the control module to the vacuum regulator must not exceed the distance as determined through the use of the graph shown on Dwg. 25.052.190.030 for the standard tubing and pipe sizes given. If necessary, any tubing or pipe can be
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10
installed that will not give more than five inches of water differential between the module and vacuum regulator at the maximum chlori­nator feed rate. Note that the equivalent length of the fittings must be added to the tubing length to obtain the total equivalent length as shown on the graph.
2.16 Injector Arrangements for Intermittent Start-Stop Operation
If the gas feeder is to be operated intermittently in conjunction with a pump or other equipment, this is usually accomplished by one of the following:
• T wo-inch injectors with three-way shut-off valves may be fitted with
solenoid valves as shown in Dwgs. 25.100.006.122, 25.100.006.142, and/or 25.100.006.152 in this section. Material for this purpose is furnished only when specifically listed in the order.
• Other injectors may be shut off by means of an electrically operated
valve in the water supply line to the injector. In this case, flexible polyethylene or rigid PVC pipe is recommended for a minimum of three feet immediately upstream of the injector. This should reduce corrosion of metal pipe and components (valves, pump impellers, etc.) caused by diffusion of chlorine solution during shut-down periods.
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SERIES V-2000 GAS FEEDER - TYPICAL INST ALLATION
25.055.110.035
ISSUE 2 6-97
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SERIES V-2000 GAS FEEDER - TYPICAL INST ALLATION
With 2" Injector
25.055.110.070
ISSUE 2 02-00
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2" INJECTOR WITH 3/4" BALL VAL VE - TYPICAL INSTALLATION
25.055.110.075
ISSUE 0 4-87
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2" INJECTOR - INSTALLATION PIPING
Connections for Prime and Flush Operation
25.100.006.122
ISSUE 4 8-93
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2" INJECTOR - INSTALLATION PIPING
Connections for Manual Suction Shut-Off Unit
25.100.06.131
ISSUE 3 1-90
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2" INJECTOR - INSTALLATION PIPING
Connections for Intermittent Start-Stop Operation
25.100.006.142
ISSUE 2 4-93
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2" INJECTOR - INSTALLATION PIPING
Connections for Intermittent Start-Stop Operation
With Injector Suction Shut-Off Unit
25.100.006.152
ISSUE 2 8-92
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TEMPERATURE AND PRESSURE: PVC PIPE IS NOT RECOMMENDED FOR TEMPERATURES OVER 130°F OR BELOW 0°F , NOR FOR
LINES THAT MA Y BE EXPOSED TO PHYSICAL ABUSE (SEE MANUF ACTURER’S RECOMMEN­DATIONS). ONE HUNDRED FEET OF PIPE WILL EXP AND OR CONTRACT APPROXIMA TEL Y 0.7 INCHES FOR EVERY 10°F TEMPERA TURE CHANGE. MANUFACTURER’S RECOMMENDED MAXI­MUM WORKING PRESSURES SHOULD NOT BE EXCEEDED.
SUPPORT AND PROTECTION: IT IS PREFERABLE TO SUPPORT HORIZONT AL OVERHEAD LINES WITH A CHANNEL OR ANGLE
IRON PARALLEL T O THE PIPE. IF STRAP HANGERS ARE USED, SPACE THEM A T 2- TO 4-FOOT INTERV ALS, AS RECOMMENDED BY THE PIPE MANUFACTURER. PIPE SHOULD NOT REST DIRECTLY ON RODS OR WIRES. PIPE MA Y BE LAID UNDERGROUND WITH NO SPECIAL PRE­CAUTIONS OTHER THAN THOSE USED FOR IRON PIPE.
THREADING: SCHEDULE 80 PVC PIPE CAN BE CUT AND THREADED WITH STANDARD PIPE T OOLS, EITHER
HAND OR POWER DRIVEN. STANDARD DIES COMMONL Y USED FOR MET AL PIPE WILL PRO­DUCE SATISF ACTOR Y THREADS, THOUGH A 5° NEGA TIVE RAKE ANGLE IS PREFERRED. KEEP DIES CLEAN AND SHARP AT ALL TIMES. DIES THA T HA VE BEEN USED EXTENSIVEL Y FOR STEEL PIPE MAY NOT PRODUCE GOOD THREADS UNLESS RESHARPENED. USE NORMAL CUTTING SPEEDS; NO LUBRICANT OR CUTTING OIL IS REQUIRED. A TAPERED PLUG (A V AIL­ABLE FROM THE MANUFACTURER, IF DESIRED) T APPED FIRML Y INTO THE END OF THE PIPE PREVENTS DISTORTION OF THE PIPE AND DIGGING-IN BY THE DIE, AS WELL AS CORRECTS ANY SLIGHT OUT-OF-ROUND THAT MA Y EXIST . T AKE CARE TO CENTER THE DIE ON THE PIPE AND ALIGN THE THREAD TO PREVENT REDUCING THE WALL EXCESSIVEL Y ON ONE SIDE. SCHEDULE 40 PVC CANNOT BE THREADED.
THREADED JOINTS: THREADED JOINTS IN PVC PIPE REQUIRE MORE CARE THAN THOSE IN SIMILAR SIZE METAL
PIPE. IF A NON-LUBRICATING THREAD COMPOUND IS USED, THE JOINT MA Y FEEL TIGHT WHEN ONLY 2 OR 3 THREADS ARE ENGAGED. IF TEFLON T APE OR SIMILAR LUBRICA TING THREAD COMPOUND IS USED, THE JOINT MAY NOT FEEL TIGHT A T ALL, AND OVERTIGHTEN­ING—RESULTING IN CRACKED FITTINGS OR STRIPPED THREADS—CAN EASIL Y OCCUR. CARE MUST BE TAKEN T O ENGAGE THE JOINED P ARTS TO A NORMAL ENGAGEMENT OF 5 TO 7 TURNS AND NO MORE. STRAP WRENCHES ARE PREFERRED FOR ASSEMBLY, AS THE SHARP EDGES ON PIPE WRENCHES MAY SCORE AND WEAKEN THE PIPE.
FLANGED JOINTS: FOR FLANGED JOINTS, USE A FULL-FACED RUBBER GASKET AND FLA T W ASHERS UNDER
BOLTS AND NUTS. TIGHTEN OPPOSITE FLANGE BOL TS TO COMPRESS THE GASKET T O A SLIGHT DEGREE, BUT DO NOT DISTORT THE FLANGE.
SOLVENT WELD OR CEMENT JOINTS: ALW A YS USE CEMENT RECOMMENDED BY THE MANUFACTURER. ADD THINNER IF CEMENT
THICKENS FROM EXPOSURE TO THE AIR.
1. CUT PIPE WITH ORDINARY HAND OR POWER SAW . MAKE A SQUARE CUT AND REMOVE BURRS.
2. CLEAN AND DRY OUTSIDE OF PIPE AND INSIDE OF FITTING.
3. APPL Y A THIN COA T OF CEMENT TO INSIDE OF FITTING AND OUTSIDE OF PIPE. USE A NATURAL BRISTLE P AINT BRUSH. CEMENT TO BE WITHIN 1/4" BUT NOT CLOSER THAN 1/ 8" FROM END OF PIPE TO PREVENT INTERNAL BEAD FROM FORMING.
4. WHILE THE CEMENT IS STILL WET , STAB THE PIPE INTO THE FITTING AND GIVE 1/8 TURN.
5. AVOID ROUGH HANDLING FOR ONE HOUR. DEPENDING ON A TMOSPHERIC CONDITIONS, APPROXIMATEL Y 50% STRENGTH WILL BE A TT AINED IN 2 HOURS AND FULL STRENGTH IN 48 HOURS.
EZISEPIP"2/1"4/3"1"4/1-1"2/1-1"2"3"4
TNEMECFOTNIPREPSTNIOJ0505535352526121
.SNACNOLLAGDNA,TRAUQ,TNIPNIYLLAICREMMOCELBALIAVAOSLA.)74642U(SNACTNIPNIT&W/FSUMORFELBALIAVATNEMEC
PVC PIPE - INSTALLATION
Fabrication and Installation
50.830.110.011
ISSUE 12 5-98
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SECTION 3 - OPERATION
List Of Contents
PARA./DWG. NO.
Preparation for Operation ......................................... 3.1
Operation .................................................................. 3.2
Starting................................................................... 3.2.1
Stopping - For Short Periods ................................. 3.2.2
Stopping - For Extended Periods........................... 3.2.3
Adjustment of Injectors.......................................... 3.2.4
Intermittent Start-Stop Operation.......................... 3.2.5
Preparation for Winter Shut-down ........................ 3.2.6
Theory of Operation ................................................. 3.3
2" Injector Manual Operation ................................ 3.3.1
2" Injector Intermittent Start-Stop Operation........ 3.3.2
2" Injector Prime and Flush Operation .................. 3.3.3
Illustrations
Flow Diagram
Series V-2000 Gas Feeder .................................. 25.055.181.010
2" Injector - Manually Operated ......................... 25.100.181.011
2" Injector - Intermittent Start-Stop Operation .. 25.100.181.021
2" Injector - Prime & Flush Operation................ 25.100.181.031
Operation - Instructions for Manual Operation ..... 40.300.170.010
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3.1 Preparation for Operation
WARNING: HAZARDOUS GAS IS PRESENT IN THIS EQUIP­MENT DURING NORMAL OPERATION. TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR DAMAGE TO THE EQUIP­MENT, READ THIS INSTRUCTION BOOK AND THE APPRO­PRIATE GAS MANUAL BEFORE CONNECTING THIS EQUIP­MENT TO A SUPPLY OF GAS. OPERATION AND MAINTE­NANCE OF THIS EQUIPMENT MUST BE RESTRICTED TO TRAINED, QUALIFIED PERSONNEL WHO ARE COMPLETELY FAMILIAR WITH THESE INSTRUCTIONS.
NOTE: See Dwg. 40.300.170.010 for instructions for manual opera­tion.
When all connections specified under Section 2 - Installation have been made, check the gas feeder as follows:
a. If the point of application is in a main through a corporation cock or
valve, the cock or valve must be open. Push in the solution tube, if furnished, until the end is in the center third of the main. In the case of large mains, the tube may be pushed in as far as it will go.
b. With the gas supply container valve(s) shut off, ensure that there is
water at the point of application ready for operation.
c. Turn on the water supply to the injector with the V-notch plug closed
all the way (clockwise). (For the two-inch injector, turn the injector shut-off valve to the ON position.) Turn on the gas supply.
d. Open the V-notch plug all the way (counterclockwise). Proper injec-
tor action may be determined by the observation of at least six inches of mercury vacuum on the injector vacuum gauge on the control module when the machine is operating at maximum capacity .
e. While the injector is operating and the gas supply is off, observe the
float in the rotameter. If the float is not resting on the bottom stop, a vacuum leak ahead of the rotameter is indicated. If this is observed, the leak may be in one of the following places:
(1) At the ring gasket at the bottom of the rotameter. This can be
corrected by proper lubrication of the ring gasket with a film of Halocarbon grease and by ensuring that the rotameter is seated on the ring gasket.
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(2) At any tubing connector or pipe fitting in the gas supply line. This
may be corrected by tightening the connector or fitting, or by replacing any defective connector O-ring.
f. Check the following to be sure all connections are tight:
(1) The V-notch extension chamber through which the V-notch plug
travels.
(2) The gasket at the bottom of the differential regulating valve.
(3) The connection of both ends of the plastic tubing on the gas dis-
charge line to the injector .
NOTE: Vacuum leaks ahead of the rotameter, as listed in preceding step e, will result in errors in gas feed. Vacuum leaks after the rota­meter, as listed in step f, may impair the performance of the injector.
g. Close the V-notch plug all the way (clockwise).
3.2 Operation
NOTE: The following procedure assumes all preparatory steps and leak tests have been completed.
3.2.1 Starting
a. Turn on the gas supply at the supply container valve and the vacuum
regulator. If there are two units (automatic switchover system), turn on only the one on the supply container that is to be used first.
WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIP-MENT DAMAGE, DO NOT OPEN THE GAS SUPPLY CONTAINER VALVE MORE THAN ONE COMPLETE TURN. THIS WILL PERMIT MAXIMUM DISCHARGE AND CAN ALSO BE TURNED OFF QUICKLY IN CASE OF A GAS LEAK.
b. Turn on the water supply to the injector. (For two-inch injector, turn
on the injector shut-off valve.)
c. The feed rate will be regulated by the control device. Dosage adjust-
ments permit matching the desired feed rate to the flow signal.
d. For automatic switchover systems, turn on the gas supply at the sec-
ond supply container and vacuum regulator.
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3.2.2 Stopping - For Short Periods
Turn off the injector water supply. (For two-inch injector, turn off the injector shut-off valve.)
3.2.3 Stopping - For Extended Periods
a. Turn off the gas supply at each supply container valve.
b. Operate the injector until the supply vacuum gauge reads 100 inches
of water, and then turn off the vacuum regulator. Continue injector operation for at least three minutes to remove all gas from the ma­chine.
c. Turn off the injector water supply . (For two-inch injector, turn of f the
injector shut-off valve.)
3.2.4 Adjustment of Injector
Fixed throat injectors are not adjustable. Other injectors may be adjusted by means of an adjusting screw or knob at the bottom of the injector. A vacuum of at least six inches of mercury is required to obtain maximum feed. If the minimum vacuum cannot be obtained, check the actual hydrau­lic conditions against those specified on the order before attempting any service.
To adjust the injector for maximum suction power, start the gas feeder with the feed rate at the maximum required. Turn the adjusting screws clock­wise (up) or counterclockwise (down) until the highest vacuum is ob­tained. To adjust the injector for minimum water usage, start the gas feeder and set the feed rate at the maximum required. Screw in (up) on the adjusting screw until the vacuum is just over the minimum required.
3.2.5 Intermittent Start-Stop Operation
In some cases, it is necessary to start and stop the gas feeder in synchronism with other equipment. A common situation is one where the gas feeder must operate when a water supply pump operates and must stop when the pump stops.
In this case, an electrically operated solenoid water valve is installed in the main injector water line. The valve is wired into the water supply pump motor circuit so it will operate to open the water supply to the injector when the pump is on, and to shut off the water supply to the injector when
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the pump is off. In this manner, the gas feeder is prevented from delivering gas to the point of application unless the pump is operating.
3.2.6 Preparation for Winter Shut-Down
If the gas feeder is to be shut down for an extended period during freezing weather, the following procedure must be followed:
a. Operate the injector with the gas supply turned off at the supply con-
tainer valve(s) until the supply vacuum gauge reads 100 inches of water, then turn off the vacuum regulator. Continue injector opera­tion for at least three minutes to remove all gas from the machine.
b. Shut off the water supply and drain the line to the injector.
c. Drain the solution discharge line and prevent any water flow into the
line.
d. Drain any water in the injector .
NOTE: If the control module is to be removed for storage, seal the gas inlet fitting and all gas lines with rubber stoppers to prevent the entrance of atmospheric moisture during the storage period. If a pump is used, follow the pump manufacturer instructions for ex­tended shutdown.
3.3 Theory of Operation
USF/W&T Gas Feeders and accessories are designed to control and indi­cate the rate of flow of chlorine, to provide a simple means of manually setting the feed rate at any value within the range of the machine, to mix the gas with water, and to deliver the resultant solution to the point of application. This equipment operates in response to an external electrical signal, but a simple release mechanism permits the operator to assume manual control at any time (see Dwg. 40.300.170.010).
In the gas feeder described in this manual, the function of the injector is to produce a vacuum to draw gas from the control module and to mix this gas with the water flowing through the injector. A diaphragm check is built into the injector to prevent a back flow of water into the control module if the injector water supply is shut off with pressure on the injector discharge or if the injector discharge line is restricted. Proper operation of the injector is dependent on the inlet pressure being sufficiently higher than the dis­charge pressure. In the control module, the differential regulating valve throttles the injector vacuum to maintain a constant drop across the V-
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notch variable orifice. Thus the flow through the orifice is entirely a func­tion of the size of the orifice as determined by the position of the V-notch plug as set by a positioner in response to an external electric signal.
Gas under pressure enters the vacuum regulator. From the vacuum regu­lator, the gas, under a controlled vacuum, passes to the control module through connecting pipes and then through a rotameter (feed rate indica­tor) causing the float to indicate the rate of flow on an easily read scale. As stated above, the rate of flow is controlled by the position of the V-notch variable orifice across which a constant differential at less than atmo­spheric pressure is maintained by the operation of the differential regulat­ing valve. From the differential regulating valve, gas passes to the injector where it is mixed with water. The resultant solution is discharged to the point of application.
3.3.1 2" Injector Manual Operation (See Dwg. 25.100.181.011)
• Application Against Pressure
When the three-way valve is in the ON position, water flows from the injector inlet through a strainer (A) and the three-way valve (B) to the chamber (C). Pressure in the chamber (C) overcomes the force of the spring (D) and opens the plug (E) the distance determined by the setting on the adjuster screw (F), permitting water to flow through the injector. The flow of water through the injector creates a vacuum, which pulls the diaphragm (G), which opens the seat (H) and permits gas to be drawn from the gas feeder.
When the three-way valve is turned to the OFF position, pressure in the chamber (C) is relieved and a spurt of water passes through the OFF port in the three-way valve to waste. The spring (D) closes the plug (E) and, with no water flowing through the injector to create a vacuum, the spring (J) closes the seat (H) to prevent water on the injector discharge from backing up into the gas feeder.
• Application Against Negative Head
If the injector described above was used where a negative head existed at the injector discharge, when the injector was shut down, this suction might act on the diaphragm (G) with sufficient force that the spring (J) could not close the seat (H), with the result that gas would be drawn from the gas feeder.
To prevent this, an injector suction shut-off unit is added to the injec­tor. When the three-way valve is in the OFF position, this unit, by the
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force of the spring (K) through the diaphragm (L) and the attached linkage, exerts a pull on the diaphragm (G) and holds the seat (H) closed. When the three-way valve is in the ON position, pressure from the chamber (C) is transmitted to the diaphragm (L) and the injector operates as described above.
3.3.2 2" Injector Intermittent Start-Stop Operation (See Dwg. 25.100.181.021)
When the injector is connected to operate in conjunction with a pump, a solenoid valve is added so that, when the three-way valve is in the START­STOP position, electrical operation of the solenoid performs the same function as manual operation of the three-way valve as previously de­scribed. When the solenoid is energized, water passes from the injector water supply through the strainer (M), then through the solenoid (N) and the three-way valve to the chamber (C). When the solenoid is de-ener­gized, the water supply is cut off and the exhausted port is opened, permit­ting the pressure chamber (C) to be relieved to waste.
3.3.3 2" Injector Prime and Flush Operation (See Dwg. 25.100.181.031)
In applications such as the intermittent desliming process, it is desirable to run water through the system before and after chlorination. This is accom­plished with a two-solenoid system. Operation is a follows: Both three­way valves are set in the START-STOP position. Energizing only the right-hand solenoid (WV) passes water to the chamber (C) causing the plug in the injector to open and water to flow through the injector for priming. The injector suction shut-off unit prevents the flow of gas until the chlorination period when the left-hand solenoid (CSV) is energized. At the end of the chlorination period, the left hand solenoid is de-energized and the injector shut-off unit stops the flow of gas. Water continues to flow through the injector for flushing until the end of the cycle, when the right­hand solenoid is de-energized. Operation of the solenoids is usually ac­complished by use of a program clock in which each portion of the cycle may be fixed by setting adjustable cams.
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V-NOTC H VA R IABLE ORIFICE
VACUUM DIFFERENTIAL REGULATING VALVE
26" TO 58" WATER VACUUM
14" TO 42" WATER VACUUM
VACUUM SUPPLY GAUGE 13" TO 48" WATER VAC U UM
INJECTOR VACUUM GAUGE 6" MERCURY MINIMUM (6.5" MERCURY MINIMUM FOR FEED RATES ABOVE 2000 LBS CHLORINE PER 24HRS OR EQUIVALENT FOR OTHER GASES.)
ROTAMETER
MANUAL FEED RATE ADJUSTER
PRESSURE VENT
PRESSURE CHECK ­PRESSURE REL IEF VALVE, OPENS AT: 10" TO 20" WATER PRESSURE
13" TO 35" WATER VACUUM
STANDARD
V
ACUUM REGULATOR
OPERATING GAS MANIFOLD
AUTOMATIC SWITCHOVER VACUUM REGULATOR (SWITCHOVER: 32" TO 42" WATER)
STANDBY GAS MANIFOLD
2" INJECTOR
INJECTOR WA TER SUPPLY
SOLUTION DISCHARGE
WALL-MOUNTED GAS FEEDER - FLOW DIAGRAM
25.055.181.010
ISSUE 1 5-97
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FOR APPLICATION AGAINST PRESSURE
WITH SUCTION SHUT-OFF UNIT
FOR APPLICATIONS NEGATIVE HEAD
2" INJECTOR - FLOW DIAGRAM
Manually Operated
25.100.181.011
ISSUE 4 5-97
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FOR APPLICATION AGAINST PR ESSURE
FOR APPLICATION AGAINST PR ESSUREFOR APPLICATION AGAINST PR ESSURE
FOR APPLICATION AGAINST PR ESSURE
WITH SUCTION SHUT-OFF UNIT
FOR APLICATION A GAINST NEGATIVE HEAD
2" INJECTOR - FLOW DIAGRAM
Intermittent Start-Stop Operation
25.100.181.021
ISSUE 3 5-97
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2" INJECTOR - FLOW DIAGRAM
Prime & Flush Operation
25.100.181.031
ISSUE 3 5-77
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INSTRUCTIONS FOR MANUAL OPERATION - OPERATION
Positioner
40.300.170.010
ISSUE 0 10-95
A. DISENGAGE THE MOTOR BY PULLING THE KNOB OUTWARD. B. ADJUST THE GAS FEED RATE AS DESIRED BY ROT ATING THE
KNOB.
C. TO RETURN TO AUTOMATIC CONTROL, PRESS THE KNOB AND
ROTATE THE KNOB SLIGHTLY UNTIL GEAR TEETH ENGAGE.
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SECTION 4 - SERVICE
List Of Contents
PARA./DWG. NO.
General Care of Equipment...................................4.1
Checking for Leaks ............................................4.1.1
Plastic Parts........................................................4.1.2
Cleaning Parts .......................................................4.2
Inspection..............................................................4.3
Tools .....................................................................4.4
Gaskets/O-Rings ...................................................4.5
Changing Gas Supply Cylinders............................4.6
Injector..................................................................4.7
Dirty Water Strainer .............................................4.8
Installation of Throat and Tailway ........................4.9
Removal of V-Notch Plug ....................................4.10
Maintenance..........................................................4.11
Performance Check............................................4.11.1
Cleaning .............................................................4.11.2
Cleaning Rotameter ...........................................4.11.3
Cleaning V-Notch Plug......................................4.11.4
Cleaning Injector Throat and Tailway ...............4.11.5
Cleaning 3/4" Fixed Throat Injector
(Standard) .......................................................4.11.6
Cleaning 3/4" Fixed Throat Injector
(Anti-Syphon) .................................................4.11.7
Cleaning 1" Fixed Throat Injector (Standard) ...4.11.8 Cleaning 1" Fixed Throat Injector
(Anti-Syphon) .................................................4.11.9
Periodic Preventive Maintenance..........................4.12
Auxiliary Cylinder Valve....................................4.12.1
Removal of Injector Plug ...................................4.12.2
Replacement of Bellofram..................................4.12.3
Vacuum Valve ...................................................4.12.4
Vacuum Gauges.................................................4.12.5
Adjustments of V-Notch Plug Linkage..............4.12.6
Troubleshooting.................................................4.12.7
Warning Summary Page........................................2 Pages
Caution Summary Page.........................................1 Page
Illustrations
Service
Installation of Rotameter ................................25.055.151.010A&B
Zero Position of Plug ......................................25.200.150.010
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WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT, EXCEPT IN CASES OF LEAK DETECTION OR CALIBRATION ADJUSTMENTS, THE GAS SUPPLY MUST BE COMPLETELY SHUT OFF AT THE GAS SUPPLY CONTAINER(S), AND THE GAS IN THE SYSTEM EXHAUSTED BEFORE SERVICING THE EQUIPMENT. TO DO THIS, TURN OFF THE GAS SUPPLY AT THE CONTAINER VALVE, WAIT UNTIL THE SUPPLY VACUUM GAUGE SHOWS 100 INCHES OF WATER AND THE ROTAMETER FLOAT RESTS ON THE BOTTOM STOP, AND THEN TURN OFF THE INJEC­TOR WATER SUPPLY.
4.1 General Care of Equipment
Maintenance is simplified if certain general precautions are taken. These are usually easy to accomplish and contribute to reducing maintenance costs by maintaining normal operating conditions. The recommended pre­cautions are as follows.
4.1.1 Checking for Leaks
WARNING: TO AVOID POSSIBLE SEVERE PERSONAL IN­JURY, IT IS GOOD PRACTICE TO HAVE AN APPROVED GAS MASK AVAILABLE WHEN MAKING LEAK CHECKS.
• CHLORINE LEAKS
WARNING: TO AVOID POSSIBLE SUFFOCATION, SEVERE PERSONAL INJURY, OR EQUIPMENT DAMAGE, DO NOT TOLERATE ANY LEAKS. THEY ALWAYS GET PROGRES­SIVELY WORSE AND MUST BE CORRECTED PROMPTLY.
NOTE: For leak testing, use USF/W&T U409 or Commercial 26° Baume’ aqua ammonia. Household ammonia is not strong enough.
A bottle of aqua ammonia is furnished for checking leakage of chlorine
gas at joints, valves, etc. Hold the moistened dauber close to the joint
or suspected leakage area. If leakage exists, a white cloud will form.
When a leak is found, immediately shut off gas supply and remove the
escaped gas by ventilation. To remove all gas from the equipment,
continue injector operation until the supply vacuum gauge reads 100
inches of water and the rotameter float rests on the bottom stop.
WARNING: ESCAPED GAS MUST BE EXHAUSTED TO OUT­SIDE ATMOSPHERE. THE EXHAUST SYSTEM MUST TERMI-
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NATE IN AN AREA WHERE GAS FUMES CANNOT CAUSE INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT. DO NOT TERMINATE THE EXHAUST SYSTEM AT A LOCATION ROUTINELY USED BY PERSONNEL, SUCH AS WORK AREAS OR PATHWAYS, NOR NEAR WINDOWS OR VENTILATION SYSTEM INTAKES.
Eliminate the leak before proceeding.
As a routine practice, check gas connections for leaks once a day.
Green or reddish deposits on metal parts indicate possible leaks. No
gas odor should be in evidence around equipment, except when a joint
is temporarily opened.
CAUTION: When any connection is broken even for a short time, immediately plug the resultant openings with a rubber stopper or equivalent to prevent the entrance of moisture. Moisture must be excluded from any part of the equipment that is normally exposed to dry chlorine only. While dry chlorine is non-corrosive, moist chlorine is extremely corrosive to common metals, such as brass or steel.
• W ATER LEAKS
As a matter of routine maintenance, tolerate no water leaks. Repair all
water leaks as soon as they are discovered.
4.1.2 Plastic Parts
Whenever threaded plastic parts are assembled, use Teflon tape or Halo­carbon grease on the threads to prevent the parts from freezing together. In general, do not use tools to make up plastic connections. Make this type of connection by hand.
4.2 Cleaning Parts
If the rotameter tube, the rotameter float, the V-notch plug, or any valve seats or passages become contaminated with impurities sometimes found in the gas, remove and clean them. Most of the residue that accumulates on the parts can be removed with warm water and a detergent. Pipe clean­ers or soft brushes may facilitate cleaning but wire brushes, scrapers, and the like should be avoided as they will damage the parts. Refer to the appropriate section in this instruction book.
WARNING: DO NOT USE HYDROCARBONS OR ALCOHOLS BECAUSE RESIDUAL SOLVENT MAY REACT WITH THE GAS.
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SOLVENTS CAN PRODUCE SERIOUS PHYSIOLOGICAL EF­FECTS UNLESS USED IN STRICTEST COMPLIANCE WITH THE SOLVENT MANUFACTURER’S SAFETY RECOMMENDA­TIONS.
All traces of detergent or moisture must be removed from the parts before they are returned to service. Do not use heat on plastic parts.
4.3 Inspection
After the disassembled parts are cleaned, and prior to reassembly, perform the following:
a. Check for physical damage to removed parts (chipped, cracked, dam-
aged threads, etc.). Replace damaged parts.
b. Discard and replace all removed O-rings, seals, and gaskets.
c. Check diaphragms for chafing or cracking. Replace damaged dia-
phragms.
4.4 Tools
When working with screws, bolts, nuts, and other hardware, use the proper size tools to avoid damage to screw heads, nuts, etc. This precaution will make it easier to remove these parts when necessary.
4.5 Gaskets/O-Rings
Keep a supply of gaskets and O-rings on hand so that gasketed joints can be maintained in proper condition. A regular replacement program for gaskets will do much to eliminate operating difficulties. The preventive maintenance kit includes a set of gaskets.
WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIP-MENT DAMAGE, NEVER REUSE GASKETS. AL­WAYS REPLACE WITH A NEW GASKET OF THE PROPER SIZE AND MATERIAL AS IDENTIFIED ON THE EQUIPMENT PARTS DRAWING.
4.6 Changing Gas Supply Cylinders
Refer to the separate instruction book provided with the vacuum regulator for detailed instructions and precautions.
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4.7 Injector
The injector is a highly important part of the gas feeder. Proper operation of the system depends upon good injector performance. Each gas feeder is equipped with an injector that is selected at the factory to suit the installation conditions. Before shipment, the gas feeder is tested under stated operating conditions to insure that it will deliver the required flow of gas when operated under the hydraulic conditions specified on the USF/ W&T shipping order. If difficulty is experienced in obtaining the specified capacity at time of installation, check the injector operating water pressure and the backpressure to see that they conform with the values specified on your order. If operating difficulties are encountered after the gas feeder has been in operation, study the injector parts drawing so that you are com­pletely familiar with the assembly of the injector before servicing.
4.8 Dirty Water Strainer
A strainer is required in the water line ahead of the injector to avoid plugging of the injector throat ports by foreign material. If sufficient ma­terial is allowed to build up on the strainer surface, the resultant pressure drop across the strainer reduces the injector operating water pressure. If the pressure drop is excessive, the injector will not be able to induct the required gas flow. Regular periodic inspection and cleaning of the strainer will minimize this possibility.
4.9 Installation of Throat and Tailway
The throat and tailway must be assembled as shown on the parts drawing. If faulty injector action is suspected, inspect the gaskets and O-rings and replace them if there is any doubt about their condition.
4.10 Removal of V-Notch Plug (See Dwg. 25.055.000.052)
NOTE: If desired, the V-notch plug can be removed from the front of the module by removing the top front panel. Insert the fingertips of one hand in recesses at lower front of the panel, hold the top of the panel with the other hand, and swing outward and push upward.
a. Shut down the gas feeder and exhaust all gas as directed under para-
graph 3.2.3, Stopping - For Extended Periods.
b. Pull knob out and rotate to lower clamp as far as possible.
c. Disconnect clamp.
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d. Unscrew extension chamber (39).
e. Pull plug straight down until the plug is free.
f. Reassemble in reverse order.
4.11 Maintenance
Maintenance of a Series V-2000 Gas Feeder consists of
three periodically
performed operations:
• Periodic Performance Checks to detect the onset of any deteriorating conditions before their progress leads to serious malfunction.
• Periodic Cleaning to remove contaminants and deposits brought to the vacuum regulator(s) and control module by the gas flow and to the injector by the water flow .
• Periodic Preventive Maintenance to disassemble, inspect, clean, and accomplish recommended parts replacement. Kits of replacement parts required for this periodic maintenance are available and are listed in Section 6 - Preventive Maintenance Kits and Spare Parts List.
PROTECT YOUR EQUIPMENT INVESTMENT
MINIMIZE DOWNTIME
REORDER A PREVENTIVE MAINTENANCE KIT NOW
KEEP ONE ON HAND
NOTE: If the gas feeder is used seasonally or with a long-term shut­down, the preventive maintenance should be performed prior to startup.
4.11.1 Performance Check
To assure that all elements of your system are functioning in a normal manner it is recommended that the following checks be made at approxi­mately three-month intervals. These checks are easy to perform and re­quire no tools.
a. With the gas turned on at the supply container valve and at the vacuum
regulator, and with the injector operating, vary the feed of the gas feeder through its full range. The gas feeder should feed steadily and hold any rate set--from the maximum of the rotameter down to 1/ 20th of maximum. The rotameter float should not stick or behave erratically at any point.
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b. With the injector still operating, turn off the gas at the supply con-
tainer valve. In a few moments the vacuum gauge should indicate 100 inches of water and the indicator on the front of the vacuum regulator should move to the EMPTY position. After initially rising, the rota­meter float will sink lower and lower in the tube until finally it is resting on the bottom stop. Decrease the feed rate if necessary to prevent the float from bouncing violently and damaging the glass tube. An incorrect vacuum reading indicates either inadequate injector vacuum or an air leak into the system. Failure of the float to settle down indicates an air leak somewhere upstream of the rotameter .
c. When the vacuum level is 100 inches of water and the rotameter float
has settled down, turn off the injector operating water. A rapid de­crease in vacuum indicates an air leak somewhere in the system.
d. If the system is equipped with automatic switchover units, operate
the gas feeder with only one unit turned on. Turn on the second unit and then close the supply container valve on the container originally feeding. The vacuum level will momentarily increase and then de­crease and the gray knob on the front of the second unit should be observed to snap down as it assumes the feeding function. Repeat the procedure reversing which container is turned on first to check that the opposite one will also pull in automatically . If either unit does not switch on automatically, refer to the vacuum regulator instruction book.
e. Close the supply container valve(s). Shut off the injector and let nor-
mal backpressure remain. Remove the tubing from the gas inlet con­nection at the injector. Note if any water drips from the end of the disconnected tubing (there should be none) and leave the tubing dis­connected for approximately 10 minutes. Note if any water appears at the outer end of the connection fitting on the injector . If any water is seen, service the injector back check.
f. With the injector shut off and the supply container valve closed, turn
the vacuum regulator off. Remove the tubing from its connection on the unit. Check for leaks per paragraph 4.1.1, Checking for Leaks, to verify that the unit shuts off tightly (no white vapors). A slight trace of vapor at the moment of disconnection may be ignored but any con­tinuing vapor formation is an indication of gas passing the valve seat. If continuing vapor formation is observed, service the unit stem and seat parts.
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4.11.2 Cleaning
At intervals as tabulated below:
METIECNANETNIAMMROFREPOTNEHW
rotalugeRmuucaV.koobnoitcurtsnietarapesotrefeR
retematoRehtedisnineeserastisopednehW
enoniskcitstaolfehtroebutssalg
.ecalp
gulPhctoN-V.retematorsaemitemastA
yawliaT&taorhTrotcejnI.shtnomxisyrevE
NOTE: The actual frequency of cleaning will depend on calendar time, the feed rate and amount of gas fed, the care exercised in cylin­der changing, the source of gas, and the quality of the operating water. The above maintenance schedule provides recommended clean­ing intervals; however, your own operating experience is the best guide to preventive maintenance and may result in significant varia­tions from the recommended schedule.
4.11.3 Cleaning Rotameter
If a milky-white, powdery-white, green-slimy, or brown-oily deposit is visible inside the rotameter tube, or if the float has particles clinging to it or tends to stick to the tube wall at lower feeds, it is time to clean the rotameter. Proceed carefully to avoid dropping the glass tube or losing the float down a floor drain or grating. To facilitate handling the float, have a clean cup, such as a coffee cup or a small beaker, and a pair of tweezers on hand before starting. Proceed as follows:
a. Turn the knob on the vacuum regulator(s) to OFF. After the supply
vacuum gauge reads 100 inches of water and the rotameter float rests on the bottom stop, turn off the injector operating water.
b. Remove rotameter. Take care not to lose the end stops, the float, or
any of the O-rings. See Dwg. 25.055.151.010.
c. Place the end stops and float into the cup mentioned above.
d. Many gas contaminants are soluble in water . Hold the tube end under
running warm (110-125°F) water so that the water enters the tube at one end and exits at the other to flush out deposits. Alternately , soak the tube in a container of warm water for about 30 seconds. Then
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hold the tube, half full with water, with palms capping the ends, and shake vigorously endwise for a few seconds. Discharge the water and repeat until clean. A common pipe cleaner may be used to scrub the interior. A deter gent will promote cleaning action.
WARNING: DO NOT USE HYDROCARBONS OR ALCOHOLS BECAUSE RESIDUAL SOLVENT MAY REACT WITH THE GAS. SOLVENTS CAN PRODUCE SERIOUS PHYSIOLOGICAL EF­FECTS UNLESS USED IN STRICTEST COMPLIANCE WITH THE SOLVENT MANUFACTURER’S SAFETY RECOMMENDA­TIONS.
e. Drain and let dry. Do not use a pipe cleaner as a drying tool because
the lint from it will stick to the tube interior. Place the tube at an angle between a horizontal and a vertical surface (as between a shelf and a wall) with both ends open so air can flow through. Drying will be hastened by heat, as from a light bulb nearby. Do not blow through the tube as moisture from the breath will condense on the tube walls.
f. To clean the float, pour about an inch of warm to hot (130-150°F)
water into the cup containing the float. Grasp the float with tweezers and shake it side to side while submerged for a few seconds. Release the float and pick it up again and repeat the action several times so all surfaces are washed. Hold the float with the tweezers, discard the wash water, and repeat the above. A few drops of detergent will im­prove the process. Do not use your fingers to hold the float.
g. Allow the float to dry on a clean surface and then, with tweezers,
place it in a clean, dry cup.
NOTE: Do not attempt to dry the float with a rag or paper towel, as electrostatic forces will make lint and other particles stick to the float.
h. Clean stops with water and dry thoroughly before reassembly .
i. When tube, float, and stops are clean and dry, wipe a thin film of
Halocarbon grease on the bottom O-ring and proceed with reassem­bly as described in Section 2 - Installation. Proceed to paragraph 4.11.4, Cleaning V-Notch Plug.
4.11.4 Cleaning V-Notch Plug (See Dwg. 25.055.000.052)
The same contaminants seen in the rotameter are in the gas stream flowing through the V-notch orifice and may also deposit at this point. When the rotameter is cleaned, clean the V-notch plug at the same time. If, at any
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time, float movement in the rotameter is not proportional to V-notch plug adjustment, as shown by a sudden marked rise or drop for a small amount of plug adjustment, the V-notch plug requires cleaning.
a. Turn the knob on the vacuum regulator(s) to OFF. After the supply
vacuum gauge reads 100 inches of water and the rotameter float rests on the bottom stop, shut off the injector water supply.
b. Remove the V-notch assembly completely from the control module.
c. Using running water or a cup full of water and a small, stiff brush
(such as a toothbrush), scrub out the V-notch groove and the shank of the plug. Do not use a knife, a scraper, or a file to clean out the groove. Dissolving action and scrubbing are all that is required.
WARNING: DO NOT USE HYDROCARBONS OR ALCOHOLS BECAUSE RESIDUAL SOLVENT MAY REACT WITH THE GAS. SOLVENTS CAN PRODUCE SERIOUS PHYSIOLOGICAL EF­FECTS UNLESS USED IN STRICTEST COMPLIANCE WITH THE SOLVENT MANUFACTURER’S SAFETY RECOMMENDA­TIONS.
d. Dry the plug with a clean cloth or paper towel.
e. Remove the seal, the clamping screw (36), and the extension cham-
ber. Clean and inspect the orifice and the O-ring (40) and replace them, if necessary .
f. Wipe a thin film of Halocarbon grease on the gaskets of the V-notch
assembly . Reinstall it in the control module and resume operation.
4.11.5 Cleaning Injector Throat and Tailway
The injector will not operate properly unless all the ports are clear. This point is easily checked visually after the throat has been removed.
Water containing carbonates, manganese, or iron will frequently leave a deposit in injector tailways. As this deposit increases in thickness, it can become scaly or rough and adversely affect pressure recovery or increase backpressure so that the injector fails to develop adequate operating vacuum. Such deposits are readily recognizable by their black or reddish color. They may be removed by immersing the throats in dilute (10%) hydrochloric acid, known commercially as muriatic acid.
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WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIP-MENT DAMAGE WHEN USING HYDROCHLORIC ACID, OBSERVE ALL SAFETY PRECAUTIONS RECOM­MENDED BY THE ACID MANUFACTURER/SUPPLIER.
If the upstream strainer becomes corroded or perforated and passes a small pebble or other tramp material, such particles can partially plug the throat and prevent adequate flow. Water containing suspended silt or sand par­ticles can erode the opening in the throat. As this opening is enlarged, the water velocity decreases, thereby decreasing the vacuum developed.
The injector should develop a dynamic vacuum of at least six inches of mercury at maximum capacity flow rate. At lower gas feed rates it tends to be higher for the same hydraulic conditions. With the gas completely shut off, the static vacuum should be about 25 to 28 inches of mercury.
If the gas feeder fails to operate, inadequate vacuum is the most common reason and the injector is the first place to check. Proceed as described in Paragraph 4.12.7, Troubleshooting.
4.11.6 Cleaning 3/4" Fixed Throat Injector (Standard) (See Dwg. 25.200.002.010)
The check valve prevents water from the injector from being drawn back by the vacuum prevailing at shutdown into the control unit and toward the vacuum regulator during the OFF period.
In continuous or nearly continuous operation, this valve is actuated very little, and the recommended annual check is principally to ensure cleanli­ness. In automatic start-stop operation, the check valve can accumulate thousands of opening and closing cycles in six months or less and wear becomes a consideration in addition to clean surfaces. For either interval the procedure is as follows:
• Cleaning Injector Unit Diaphragm Backcheck.
a. Shut off injector operating water.
b. T ake steps to prevent water flowing back toward the injector from
the point of application.
c. Unscrew gas line tubing nut and remove tubing.
d. Unscrew injector body union nut (10).
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e. Unscrew valve stem (8) in the center of the top of the upper body
(32). Wipe the surface of the spherical tip of valve stem with a clean cloth or paper towel to remove any loose material. Soak briefly in 10% muriatic (hydrochloric) acid if there are any depos­its that do not wipe away with plain water . If the spherical surface is indented, worn, eroded, or scratched, replace valve stem.
WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE WHEN USING HYDROCHLORIC ACID, OBSERVE ALL SAFETY PRECAUTIONS RECOM­MENDED BY THE ACID MANUFACTURER/SUPPLIER.
f. Using a blunt tool, remove the O-ring (31) from the valve seat (9)
(diaphragm clamping screw). Discard the O-ring.
g. Reassemble the valve stem to the upper body and replace the valve
seat O-ring and diaphragm clamping O-ring (outer) prior to as­sembling the injector body union nut (10).
• Cleaning Poppet Check
a. Unscrew the inlet adapter and discard O-ring (2).
b. Remove the poppet (4) and remove and discard the O-ring (3)
from the poppet.
c. Replace the poppet O-ring (3).
d. Replace the inlet O-ring (2). Wipe a thin film of Halocarbon grease
on the O-ring before installing it.
e. Reassemble the poppet and inlet adapter.
4.11.7 Cleaning 3/4" Fixed Throat Injector (Anti-Syphon) (See Dwg. 25.200.002.020)
The check valve prevents water from the injector from being drawn back by the vacuum prevailing at shutdown into the control unit and toward the vacuum regulator during the OFF period.
In continuous or nearly continuous operation, this valve is actuated very little, and the recommended annual check is principally to assure cleanli­ness. In automatic start-stop operation, the check valve can accumulate thousands of opening and closing cycles in six months or less and wear becomes a consideration in addition to clean surfaces. For either interval the procedure is as follows:
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• Cleaning Injector Unit Diaphragm Backcheck.
a. Shut off injector operating water.
b. T ake steps to prevent water flowing back toward the injector from
the point of application.
c. Unscrew gas line tubing nut and remove tubing.
d. Unscrew injector body union nut (10).
e. Unscrew valve stem (8) in the center of the top of the upper body
(32). Wipe the surface of the spherical tip of valve stem with a clean cloth or paper towel to remove any loose material. Soak briefly in 10% muriatic (hydrochloric) acid if there are any depos­its that do not wipe away with plain water . If the spherical surface is indented, worn, eroded, or scratched, replace valve stem.
WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE WHEN USING HYDROCHLORIC ACID, OBSERVE ALL SAFETY PRECAUTIONS RECOM­MENDED BY THE ACID MANUFACTURER/SUPPLIER.
f. Using a blunt tool, remove the O-ring (31) from the valve seat (9)
(diaphragm clamping screw). Discard the O-ring.
g. Reassemble the valve stem to the upper body and replace the valve
seat O-ring and diaphragm clamping O-ring (outer) prior to as­sembling the injector body union nut.
• Cleaning Poppet Check
a. Unscrew the inlet adapter and discard O-ring (2).
b. Remove the poppet and remove the O-ring (3) from the poppet.
Discard the O-ring.
c. Replace the poppet O-ring.
d. Replace the inlet O-ring. Wipe a thin film of Halocarbon grease
on the O-ring before installing it.
e. Reassemble the poppet and inlet adapter.
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f. Proceed to paragraph c for the anti-syphon portion of the injec-
tor.
• Cleaning Anti-Syphon Injector Lower Portion
a. Unscrew lower union nut (10), carefully remove bottom cap, and
take out diaphragm assembly . Clean of f any deposits with warm (110°-125°F) water. It is not necessary to disassemble the dia­phragm unit to do this.
b. Remove O-rings (17) from guide pins (13). Clean O-ring groove
on guide pins. Do not scrape with a knife blade or any such instru­ment. Only warm water (110°-125°F) is permissible. W ipe a thin film of Halocarbon grease on the new O-rings before installing them on the guide pins (13). Loosen screws (20) 3/4 of a turn from their tight position, if disassembled.
c. Remove spring (22) and wipe off any deposits found.
d. Reinstall spring and diaphragm assembly into bottom cap. Reas-
semble bottom cap to body with union nut.
4.11.8 Cleaning 1" Fixed Throat Injector (Standard) (See Dwg. 25.200.002.030)
• Cleaning Injector Unit Diaphragm Backcheck
a. Turn off the gas supply. Allow the gas feeder to run until the float
drops and settles on the bottom stop.
b. Shut off injector operating water.
c. T ake steps to prevent water flowing back toward the injector from
the point of application.
d. Unscrew stem (11) in the center of the top of the injector. Re-
move and discard O-ring (5).
e. Wipe the surface of the spherical tip of stem with a clean cloth or
paper towel to remove any loose material. Soak briefly in 10% muriatic (hydrochloric) acid if there are any deposits that do not wipe away with plain water. If the spherical surface is indented, worn, eroded, or scratched, replace valve stem (11).
WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE WHEN USING HYDROCHLORIC
!
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ACID, OBSERVE ALL SAFETY PRECAUTIONS RECOM­MENDED BY THE ACID MANUFACTURER/SUPPLIER.
f. Wipe a thin film of Halocarbon grease on the O-ring (5) before
installing it on the stem.
g. Look through the opening in the top of the injector with a flash-
light and examine the conical hole and O-ring in diaphragm screw immediately below . If it is smooth and clean, merely reinstall the stem, making sure the large O-ring is under the head. If the coni­cal hole and O-ring show film deposits, clinging particles, or a rough surface, disassemble the injector . Unscrew the gas line union nut (15) and discard O-ring (16).
h. Remove six bolts and lift off injector flange. Carefully remove the
diaphragm assembly . Using a fine, pointed tool, pierce the O-ring (8) and remove it from the valve seat (7). Clean the conical hole in the diaphragm screw. Do not scrape with a knife blade or a tapered reamer. Scrub out with a cloth plug. Dissolve resistant deposit with 10% muriatic (hydrochloric) acid. It is not necessary to disassemble the diaphragm to do this.
WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE WHEN USING HYDROCHLORIC ACID, OBSERVE ALL SAFETY PRECAUTIONS RECOM­MENDED BY THE ACID MANUFACTURER/SUPPLIER.
i. Reassemble the valve stem (11) to the upper body (13) and re-
place the valve seat O-ring (8) and diaphragm clamping O-ring (outer).
j. Bolt the flange in place with six bolts.
• Cleaning Poppet Check
a. Unscrew adapter (34) and remove O-ring (35). Discard the O-
ring.
b. Remove poppet (21) and remove O-ring (23). Discard the O-
ring.
c. Clean threads and O-ring grooves by soaking in warm water. W ipe
a thin film of Halocarbon grease on the O-rings and threads.
!
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d. Install a new O-ring on the poppet and insert the poppet into the
holder .
e. Assemble the holder (34) to the injector body. Do not use exces-
sive force when tightening the adapter .
f. Replace the union nut O-ring (16) before reconnecting the gas
line.
4.11.9 Cleaning 1" Fixed Throat Injector (Anti-Syphon) (See Dwg. 25.200.002.040)
NOTE: When removing O-rings, use a blunt tool to pull them out. Do not damage the tightening surfaces. Apply a thin film of Halocarbon grease to the new O-rings and to the threads.
a. Follow the directions in paragraph 4.11.8.a, Cleaning One-Inch Fixed
Throat Injector (Standard), Cleaning Injector Unit Diaphragm Backcheck.
b. Unscrew the clamping nut (33) with the parts connected.
c. Remove the poppet (21). Replace the O-ring (20).
d. Remove the snap ring clip (31).
e. Remove the clamping nut (33) and spring (32).
f. Remove the clamping washer (29) and replace O-ring (35).
g. Replace the diaphragm assembly (1). Assemble with clamping disc,
clamping screw , and spring (32). Secure with snap ring (31).
h. Remove the plug (19) and replace the O-ring (20).
i. Press out the poppet seat (18). Replace the poppet seat along with
the O-ring (20). Press in the new seat using a round rod or plastic tube (16 mm) with a flat front.
j. Place the poppet into the guide (25) and screw in the clamping nut
(33) with the assembled parts.
k. Screw in the plug.
l. Replace the O-ring in the gas inlet.
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m. Secure the tailway with the retaining nut and connect to the operation
water tubing.
n. Connect the gas line.
o. Check for tightness and function.
4.12 Periodic Preventive Maintenance
Because of aging of elastomeric components and the desirability of check­ing internal zones for possible accumulations of deposits not seen in rou­tine maintenance, it is recommended that, at one-year intervals, each of the principal components of the system be completely disassembled. Before starting the work, ensure that the appropriate preventive maintenance kits are on hand.
NOTE: If the gas feeder is used seasonally or with a long-term shut­down, the preventive maintenance should be performed prior to startup.
Refer to the tabulated listing below and Section 6 of this book for appro­priate kit numbers.
Disassembly and reassembly instructions necessary to install the mainte­nance kit parts are included in the kit(s).
Servicing of USF/W&T equipment, including installation of parts from maintenance kits, should be restricted to trained, authorized personnel who are completely familiar with the entire contents of the equipment instruction book. The USF/W&T sales office or the dealer from whom you purchased the equipment can provide the preventive maintenance kits or overhaul service.
4.12.1 Auxiliary Cylinder V alve
See separate instruction book provided with vacuum regulator.
4.12.2 Removal of Injector Plug (2" Bellofram Type Injector, Dwg. 25.052.001.046)
CAUTION: If the injector plug is to be removed for cleaning or re­placement, it is essential that the plug rod (6) be held with a wrench so it cannot rotate when the plug is unscrewed. Rotation of the plug rod will cause damage to the bellofram (16).
!
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4.12.3 Replacement of Bellofram (See Dwg. 25.052.001.046)
Damage to the bellofram (16) is indicated by a continuous flow of water from the injector shut-off valve drain when the valve is in the OFF position or by failure of the injector to operate when the valve is in the ON position.
To replace the bellofram, proceed as follows:
a. Remove the adjusting screw nut (19) with the adjusting screw (21),
lock nut (20), and spring (50).
b. Remove the connecting tube (26).
c. Remove the two 1/2-inch cap bolts (49) and lower the entire lower
portion of the injector, including the plug rod (6) and plug (4).
d. Remove the old bellofram and assemble the new one on the plug rod
(16).
e. Locate the bellofram on the backing cup (15).
f. Reassemble the injector.
4.12.4 V acuum V alve
• Removal (see Dwg. 25.055.000.052)
a. Disconnect two tubing nuts (9) from top of valve (31).
b. Loosen union nut (35) and remove hex screw (12) from valve.
c. Loosen clamping screw (45) and lift off valve.
• Disassembly (see Dwgs. 25.055.000.052 & 25.056.003.010)
a. Remove seat and spring (32). Remove and discard gasket (33).
b. Take note of the relative position of valve body (1) and backing
plate (9). They must be restored to their original positions during reassembly .
c. Remove clamps (3). Lift off backing plate (9). Remove and dis-
card O-ring (2).
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d. Remove diaphragm (6). Remove machine screws (4). Remove
and discard gaskets (7).
• Reassembly
a. Refer to the cleaning procedure and clean the parts prior to reas-
sembly .
b. Wipe a thin film of Halocarbon grease onto all O-rings.
c. Reassemble in the reverse order of disassembly.
4.12.5 V acuum Gauges
CAUTION: Do not disassemble diaphragm unit from vacuum gauge.
4.12.6 Adjustment of V-Notch Plug Linkage
When the controller is receiving a zero flow signal, loosen the hex nut at the top of the rack in the control module and rotate the coupling screw until the V-notch plug is at its zero position (see Dwg. 25.200.150.010). Tighten the hex nut.
4.12.7 Troubleshooting
The following troubleshooting table is provided for determining and cor­recting most common troubles.
!
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AUTOMA TIC CHLORINA TOR - 3000LB/24HR
50
Table 4.1 - Troubleshooting With a Manometer and Vacuum Gauge
cisaB
:snoitcurtsnI
.)deefllufdna,flah,wol(wolfsagfoegnarllufehtrevomuucavehterusaeM.1
fI.steehsatadlangisnororedeefsagruoyrofmargaiDwolFehtnonevigserugifhtiwerusaemuoytahwerapmoC.2
.tnemeletxenehtkcehcdnaenolatnenopmoctahtevael,thgireraserugifeht
.melborpehttniopnipotyrassecensaskcehcekaM.3
.etairporppasikrowhcussetacidnitsilkcehcfiriaperdnaylbmessasidtnenopmocrofnoitcurtsnideliatedotrefeR.4
GNINRAW
SAGEHTFFONRUT,EGAMADTNEMPIUQEROYRUJNILANOSREPEREVESELBISSOPDIOVAOT:
RETAWFOSEHCNI001SWOHSEGUAGMUUCAVYLPPUSEHTLITNUTIAW.EVLAVRENIATNOCEHTTAYLPPUS
YLPPUSRETAWROTCEJNIEHTFFONRUT.POTSMOTTOBEHTNOSTSERTAOLFRETEMATOREHTDNA
.GNIPPOTS-NOITAREPOOTREFER.SNOITAREPOYLBMESSASIDYNAGNIMROFREPEROFEB
GNITAREPO
SMOTPMYS
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OTTAHW
ERUSAEM
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ERUSAEM
LACIPYT
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REPORP
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SAG
REDEEF
TONLLIW
PUEMOC
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ERUSSERP
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tifienihcamno
fI.enosah
onsiereht
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taretemonam
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.rotcejni
-UatcennoC retawebut retemonam
dnamaertspu
fomaertsnwod
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saghtiW
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fosehcni
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tuhssaghtiW
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tsujerusserpretawgnitarepoerusaeM erusserpkcabdnarotcejnifomaertspu
.rotcejnifomaertsnwodtsuj
kcehC.atadsuoiverphtiwerapmoC yletaidemmiwolfhtoomsrofgnipip
oN(.yawliatrotcejnifomaertsnwod
).cte,srecuder,seet,swoble
mgarhpaidhguorhtskaelriarofkcehC
.sevlavkcehcrotcejniepytmgarhpaidfo
rolanigramsimuucavrotcejnierehW
hctoN-V,enilredroberasciluardyh
rotacidnievitisneseromasilaitnereffid
ehtnahtmuucavgnitarepoetauqedafo
"gnibbob"A.eguagmuucavrotcejni
lanigramsetacidnitaolfretemator
.muucav
rotcejninaelC
dnataorht
.yawliat
ecalperroraelC
egrahcsidnoitulos
.gnibut
etauqedaedivorP
.erusserpretaw
ETON
regralA:
dnataorht
ylnoyamyawliat
ehtdnuopmoc
ehtsamelborp
wolfretaerg
retaergsetaerc
.erusserpkcab
Page 61
IM 25.055AC UA (C/6-01)
AUTOMA TIC CHLORINA TOR - 3000LB/24HR
51
Table 4.1 - Troubleshooting With a Manometer and Vacuum Gauge (Cont'd)
GNITAREPO
SMOTPMYS
ELBABORP
ESUAC
OTTAHW
ERUSAEM
OTWOH
ERUSAEM
SEULAVLACIPYT
REPORPROF
NOITAREPO
SKCEHCLANOITIDDAYDEMER
REDEEFSAG
SDEEF
YLLAMRON
HGIHTA
TUBSETAR
TONLLIW
TALORTNOC
REWOL
.SETAR
-rotalugermuucaV
tontinukcehc
gnilttorht
dleh(,yltneiciffus
elcitrapaybnepo
cirref,tsurfo
.).cte,edirolhc
mgarhpaiddabA
-reffidmuucavni
gnitalugerlaitne
ebyamevlav
gnissap-ybgnisuac hctoN-Vehtfo .evlavlortnoc
detalugeR
.muucav
muucaV
-nereffid
lait
gnitaluger
.evlav
pactcennocsiD
niwoblemorf
-kcehcerusserp
feilererusserp
atcennoC.evlav
retawgelelgnis
taretemonam
.gninepowoble
ebut-UatcennoC
retemonamretaw
ssorca
laitnereffid
.evlavgnitaluger
fosehcni53ot31
.retaw
sehcni71ot2/1-11
.laitnereffidretawfo
tasllafmuucavfietoN
rehtie,osfI.sdeefrewol
gnisuacebtsumsagroria
,hcihwenimretedoT.ti
fI.reniatnoctasagffonrut
,spordtaolfretemator
fI.gniwolfsawsagssecxe
nignikaelebtsumria,ton
.teksagatsap
muucavfopotezirusserP
gnitalugerlaitnereffid
kcehcdnariahtiwevlav
.retawniskaelrof
muucavnaelC
kcehc-rotaluger
.tinu
.steksagkcehC
ecalpeR
.mgarhpaid
REDEEFSAG
LORTNOC
YLLAMRON
WOLTA
SITUB,DEEF
CITARRE
LLUFNEHW
SIDEEF
.DETPMETTA
ROTCEJNI
MUUCAV
.LAMRON
saghguonetoN
yfsitasotgniretne
ytriD.dnamed
-rotalugermuucav
rotinukcehc
deggolcyllaitrap
.enilsag
detalugeR
.muucav
pactcennocsiD
niwoblemorf
-kcehcerusserp
feilererusserp
atcennoC.evlav
retawgelelgnis
taretemonam
.gninepowoble
fosehcni53ot31
.retaw
muucavroenilsagfI tinukcehc-rotaluger ,deggolcyllaitrapsi
lliwmuucaveht
.esaercni
NOITUAC
tatratS:
;setardeefwol
esaercniyllaudarg
tneverpotdeef
"gniwolb"
.retemonam
.erusserpylppussagkcehCmuucavnaelC
kcehc-rotaluger
.tinu
-hgihnaelC sagerusserp
.enil
etauqedaylppuS
.erusserpsag
ehtsiisp02(
rofmuminim
deeflluf
).ecnamrofrep
Page 62
IM 25.055AC UA (C/6-01)
AUTOMA TIC CHLORINA TOR - 3000LB/24HR
52
Table 4.1 - Troubleshooting With a Manometer and Vacuum Gauge (Cont'd)
GNITAREPO
SMOTPMYS
ELBABORP
ESUAC
OTTAHW
ERUSAEM
OTWOH
ERUSAEM
SEULAVLACIPYT
REPORPROF
NOITAREPO
LANOITIDDA
SKCEHC
YDEMER
REDEEFSAG
TONSEOD
SAG.DEEF
SIERUSSERP
.ETAUQEDA
ROTCEJNI
SIMUUCAV
.LAMRON
noitcennocebuT
fomaertspumorf
fopotothctoN-V
laitnereffid
evlavgnitaluger
rodetcennocsidsi
.gnikael
detalugeR
.muucav
pactcennocsiD
niwoblemorf
-kcehcerusserp
feilererusserp
atcennoC.evlav
retawgelelgnis
taretemonam
.gninepowoble
fosehcni53ot31
.retaw
-ebuttcennoc-eR .enil
fiebutecalpeR
,deknik,dekcarc
taevitcefedro
.sdne
.stunebutnethgiT
RETEMATOR
SEODTAOLF
LLAPORDTON
OTYAWEHT
MOTTOBEHT
NEHWPOTS
SISAGEHT
TAFFOTUHS
EHT
RENIATNOC
EHTDNA
SIROTCEJNI .GNITAREPO
maertspukaelriA
retematorfo
-RO­.retematorytrid
sitaolffieeS
,.e.i("evila"
eerfrognignnips
,gnitaolf
riagnitacidni
"daed"ro)wolf
aotspord,.e.i(
,tnioptnatsnoc
gni-tacidni
rotridybgnidnib
.)rettamngierof
lausiV
.ecnaraeppa
-- muucavkcehC rotaluger
,smgarhpaid
retnecgnidulcni
kcehC.slaes
feilererusserp
dnamgarhpaid
.secafrusgnitaes
Page 63
IM 25.055AC UA (C/6-01)
AUTOMA TIC CHLORINA TOR - 3000LB/24HR
53
Table 4.1 - Troubleshooting With a Manometer and Vacuum Gauge (Cont'd)
GNITAREPO
SMOTPMYS
ELBABORP
ESUAC
OTTAHW
ERUSAEM
OTWOH
ERUSAEM
LACIPYT
ROFSEULAV
REPORP
NOITAREPO
LANOITIDDA
SKCEHC
YDEMER
RETEMATOR
TONSEODTAOLF
LLAFDNAESIR
NIYLMROFINU
OTNOITROPORP
BONKHCTON-V TUBNOITATOR ROPU"SPMUJ"
YLPRAHSNWOD
LLAMSAHTIW
-VNIEGNAHC .GNITTESHCTON
-- .lausiV- - dnaylbmessahctoN-VevomeR
-Vnievoorgdepahs-Vnaelc dnahsurbhtootA(.gulphctoN
yllausueraretawmraw
).evitceffe
NOITUAC
roeparcstonoD:
-prahsahtiwevoorghctarcs
.lootdegde
REDEEFSAG
SDEEF
TUBYLLAMRON
RENIATNOC
SASSOLTHGIEW
ELACSYBWOHS
TONSEOD
HTIWEERGA
RETEMATOR
SNOITACIDNI
YBDEILPITLUM
HCAETAEMIT
.GNITTES
kaelriA
fomaertspu
.retemator
-- - - erusserP:kcehc,skaelriaroF gnitaesdnamgarhpaidfeiler
rotalugermuucav,ecafrus
retnecgnidulcni,smgarhpaid
.srotcennocgnibutdna,slaes
noitcurtsnietarapeseeS(
).koob
Page 64
IM 25.055AC UA (C/6-01)
AUTOMA TIC CHLORINA TOR - 3000LB/24HR
54
Table 4.1 - Troubleshooting With a Manometer and Vacuum Gauge (Cont'd)
GNITAREPO
SMOTPMYS
ELBABORP
ESUAC
OTTAHW
ERUSAEM
OTWOH
ERUSAEM
LACIPYT
ROFSEULAV
REPORP
NOITAREPO
LANOITIDDA
SKCEHC
YDEMER
SIHCTON-V
OTTLUCIFFID
RONRUT
YBEVOM
DNAKCAR
NEHW.NOINIP
YLBICROF
NA,DEVOM
SIKAELRIA .DETCETED
HTEETKCAR
.NEKORBERA
sagfopudliuB
tnanimatnoc
-Vnoeudiser tfahsgulphctoN
ehtnignidnibsi
laes
-RO­decrofneebsah
,laesehttsap
.nepotignihcterts
oN
stnemerusaem
.deriuqer
-- - .ylbmessahctoN-VeritneevomeR tuobarofretawmrawnikaoS
dnawercsnU.setunimowt
-VwardhtiW.pmalclaesevomer .gnir-OdnalaeshtiwgulphctoN
.gulpnaelC
mlifthgilahtiwgulpetacirbuL
elbmessaeR.esaergnobraclaHfo
pmalclaesgninethgit,straplla
,htoomsaevigothguonetsuj .gulpehtnopirggnidils,mrif
.degamadfilaesecalpeR
hteetfinoiniprokcarecalpeR
.nekorbera
ETON
dnapugulpgninnuR:
egnarllufstihguorhtnwod
ynaffoepiwlliwhtnomaecno
tierofebeudisergninnigeb
drahroykcitsasemoceb
.noitalumuccatnatsiser
Page 65
IM 25.055AC UA (C/6-01)
55
WARNING LABELS AND TAGS
The following warning labels and tags are attached to the equipment.
-----------------------------------------------------------------------------------­L2016: TO AVOID POSSIBLE SEVERE PERSONAL INJURY
FROM ELECTRICAL SHOCK, TURN OFF POWER BEFORE SERVICING.
-----------------------------------------------------------------------------------­L2708: CHLORINE, WHICH IS A HAZARDOUS CHEMICAL,
IS PRESENT IN THIS EQUIPMENT DURING NORMAL OPERATION. TO AVOID POSSIBLE SEVERE PER­SONAL INJURY OR DEATH, YOU MUST OBSERVE THE FOLLOWING PRECAUTIONS:
1. When changing chlorine supply containers you must be completely familiar with your local plant operating and emergency procedures, including the location and use of a gas mask. Recommended emergency procedures can be obtained from your chlorine supplier, the Chlorine Institute, Inc., or similar organization.
2. Do not open the chlorine supply container valve more than one complete turn. This will permit maximum dis­charge and can be turned off quickly in the event of a leak.
3. On a routine daily basis, starting at the chlorine supply container(s), thoroughly check all joints, connections, and equipment for possible chlorine leaks and immedi­ately correct any found. Do not tolerate any chlorine leaks.
4. Chlorine leaks never get better. If they are not promptly corrected, chlorine leaks always get progressively worse.
5. Never re-use gaskets in chlorine piping systems. Always have an adequate supply on hand and always use new gaskets of the correct size and material as identified on the equipment parts drawings.
6. Except in cases of leak detection or calibration adjust­ments, the chlorine supply must be shut off at the supply container valve(s) and the chlorine in the system com­pletely exhausted before servicing the equipment.
7. It is recommended practice to have an approved gas mask available, which you have been trained to use, when making chlorine leak checks and when changing chlorine supply containers.
Page 66
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WARNING LABELS AND TAGS (CONT'D)
8. The USF/W&T instruction book provided with this equip­ment furnishes complete and detailed instructions for its installation, operation, and maintenance and must be referred to for that detailed information.
9. The USF/W&T instruction book provided with this equip­ment also furnishes technical information on the charac­teristics, storage, and handling of chlorine, and must be referred to for that information. Contact your chlorine supplier, the Chlorine Institute, Inc., or similar organiza­tion to obtain more detailed information.
10. Operation and maintenance of this equipment must be restricted to trained, qualified personnel who are com­pletely familiar with these instructions.
DO NOT REMOVE THIS SIGN FROM THIS EQUIP­MENT
-----------------------------------------------------------------------------------­P60168: HAZARDOUS GAS IS PRESENT IN THIS EQUIPMENT
DURING NORMAL OPERATION.
TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT, READ THE USF/ W&T INSTRUCTION BOOK AND THE APPROPRIATE GAS MANUAL BEFORE CONNECTING THIS EQUIP­MENT TO A SUPPLY OF GAS. OPERATION AND MAINTENANCE OF THIS EQUIPMENT MUST BE RE­STRICTED TO TRAINED, QUALIFIED PERSONNEL WHO ARE COMPLETELY FAMILIAR WITH THESE INSTRUCTIONS.
THIS UNIT IS DESIGNED TO OPERATE UNDER VACUUM ONLY.
TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE, DO NOT CONNECT TO A SOURCE OF GAS UNDER PRESSURE.
DO NOT USE THIS EQUIPMENT FOR SWIMMING POOL, WATER PARK, OR SIMILAR RECREATIONAL APPLICATIONS. IT IS NOT SOLD FOR SUCH USE.
------------------------------------------------------------------------------------
Page 67
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57
CAUTION LABELS AND TAGS
The following caution labels and tags are attached to the equipment.
-----------------------------------------------------------------------------------­L2076: DO NOT DISASSEMBLE DIAPHRAGM UNIT FROM
PRESSURE SENSOR.
-----------------------------------------------------------------------------------­P4373: PULL OUT STEM TO FULL LENGTH OF CHAIN BE-
FORE CLOSING VALVE.
-----------------------------------------------------------------------------------­L2556: FOR CHLORINE, SULFUR DIOXIDE, OR CARBON DI-
OXIDE USE ONLY.
-----------------------------------------------------------------------------------­L3259: TO PREVENT DAMAGE TO MODULE, REPLACE
SHIMS UNDERNEATH MODULE AFTER PLYWOOD FEET ARE REMOVED.
-----------------------------------------------------------------------------------­L2557: FOR CHLORINE, SULFUR DIOXIDE, AMMONIA, OR
CARBON DIOXIDE USE ONLY.
------------------------------------------------------------------------------------
Page 68
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58
INSTALLATION OF ROTAMETER - SERVICE
25.055.151.010A
ISSUE 0 4-92
NOTE: FOR INSTRUCTIONS, SEE DWG. 25.055.151.010B.
Page 69
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59
TO INST ALL ROT AMETER
a. Remove the control unit front cover by gripping ft on the sides near the bottom. Swing it out while pushing up. b. Join the stops together to form a cross and insert the stops in the outlet assembly with the circular cutouts up. c. Insert the ring gasket into the outlet block. d. Install the sealing ring in the cam nut. e. Install the ring gasket in the V of the sealing ring. f. For rotameter tubes with capacities of 50-150 lb/24 hr .
(1) Adjust the inlet housing to align the scribe line with the top of clamp. (2) Install the adapter and ring gasket on the neck of the gas inlet housing. (3) Assemble the rotameter with the bottom and top stops, the float, a ring gasket and adapter on top of the tube.
g. For rotameter tubes with capacities of 250-2000 lb/24 hr:
(1) Adjust the inlet housing to align the scribe line with the top of clamp. (2) Install the bottom stop with the tubular end up. (3) Set the rotameter float with the pointed end down in the bottom stop.
h. For 3000 lb/24 hr capacity rotameter:
(1) Adjust the inlet housing to align the top edge of the housing with the top of the clamp. (2) Install the float, flat gasket, upper stop, flat gasket and adapter in the top of the rotameter .
(3) Install the flat gasket and the adapter at the bottom of the rotameter tube. i. Ensure that the knob on the cam nut is all the way to the right. j. Hold both ends of the rotameter in your hands. Engage the bottom at an angle and then swing the top back into
position. k. Rotate the cam nut to the left to lock and seal the rotameter in position. l. Replace the control unit front cover.
TO REMOVE ROT AMETER
a. Shut down the gas feeder and exhaust all gas as directed under OPERATION-STOPPING FOR EXTENDED PERIODS. b. Remove the front cover. c. Rotate the cam nut completely to the right. d. Grasp the ends of the tube in both hands. Pull the top of the tube outward. e. Lift off the tube with care. Do not drop loose parts.
INSTALLATION OF ROTAMETER - SERVICE
25.055.151.010B
ISSUE 0 4-92
Page 70
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60
THE PLUG IS AT THE ZERO POSITION WHEN THE SCRATCH LINE ON THE PLUG IS IN LINE WITH THE BOTTOM OF THE ORIFICE. THIS RESUL TS WHEN THE ELECTRONIC CONTROLLER IS RECEIVING A ZERO SIGNAL. IF ADJUSTMENTS ARE NECESSARY:
A. RETRACT RACK AND THEN LOOSEN NUT. B. UNSCREW THE EXTENSION CHAMBER CONTAIN-
ING THE V-NOTCH PLUG AND ORIFICE.
C. LINE UP THE SCRA TCH LINE ON THE PLUG WITH
THE BOTTOM OF THE ORIFICE.
D. CAREFULL Y REINST ALL THE EXTENSION CHAM-
BER INTO THE UNIT .
E. LOOSEN LOCKING NUT AND SCREW COUPLING
SCREW COMPLETELY IN.
F . USE ELECTRICAL SIGNAL FROM CONTROLLER T O
POSITION RACK A T ZERO FEED POSITION.
G. ADJUST BALL AND SCREW FOR CORRECT ALIGN-
MENT BETWEEN THE ACTUA TOR AND THE PLUG.
H. ATTACH THE NUT AND TIGHTEN.
AUTOMATIC CONTROL UNIT - SERVICE
Zero Position of Plug
25.200.150.010
ISSUE 0 10-95
Page 71
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61
SECTION 5 - ILLUSTRATIONS
List Of Contents
DRAWING NO.
Parts
Basic Components .............................................25.055.000.052A-D
Chlorine Rotameter............................................25.056.005.010A&B
V-Notch Plug Components................................25.056.004.010
Vacuum Differential Regulating Valve ..............25.056.003.010A&B
2" Injector - With Pressure-Operated Plug
Shut-Off ..........................................................25.052.001.046A&B
2" Injector - With Manually Operated Plug
Shut-Off ..........................................................25.052.001.051A&B
U19315 Injector Shut-Off Unit..........................25.100.06.111
AAA4316 1" Standard Injector .........................25.200.002.030A&B
Junction Box ......................................................25.055.000.017A&B
AAA4313 1" Anti-Syphon Injector ...................25.200.002.040A&B
Plastic 1" Fixed Throat Injector and Tailway
Details .............................................................25.200.003.010A&B
AAA4310 3/4" Standard Injector ......................25.200.002.010A&B
AAA4307 3/4" Anti-Syphon Injector ................25.200.002.020A&B
Main Connections - For Hose............................50.845.02.011
Plastic Main Connection - For 3/4" or 1"
Solution Lines With 1" Corporation Cock......50.845.06.011
Main Connection - For 1-1/2" Solution Line .....50.845.006.021
Main Connection - For 2" and 3" Rigid Plastic
Pipe .................................................................50.845.006.031
Module Enclosure ..............................................25.055.004.010A&B
GAA1046 Dual or High and Low Vacuum
Switch Connections ........................................55.116.020.015A&B
Connections For Gas Flow Transmitter
AAA7427 3000lb Series V2000 Gas Feeder ..55.114.010.020A-C
Page 72
IM 25.055AC UA (C/6-01)
62
SERIES V-2000 GAS FEEDER - P AR TS
25.055.000.052A
ISSUE 0 8-97
NOTE: FOR PARTS LIST, SEE DWGS. 25.055.000.052C&D.
Page 73
IM 25.055AC UA (C/6-01)
63
SERIES V-2000 GAS FEEDER - P AR TS
25.055.000.052B
ISSUE 1 02-00
NOTE: FOR P AR TS LIST, SEE
DWGS. 25.055.000.052C&D.
Page 74
IM 25.055AC UA (C/6-01)
64
SERIES V-2000 GAS FEEDER - P AR TS LIST
25.055.000.052C
ISSUE 0 8-97
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
Page 75
IM 25.055AC UA (C/6-01)
65
SERIES V-2000 GAS FEEDER - PARTS LIST
25.055.000.052D
ISSUE 1 02-00
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
Page 76
IM 25.055AC UA (C/6-01)
66
CHLORINE ROTAMETER - PARTS
25.056.005.010A
ISSUE 0 6-93
NOTE: FOR P ARTS LIST, SEE DWG. 25.056.005.010B.
Page 77
IM 25.055AC UA (C/6-01)
67
CHLORINE ROTAMETER - PARTS LIST
25.056.005.010B
ISSUE 0 6-93
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
Page 78
IM 25.055AC UA (C/6-01)
68
V-NOTCH PLUG COMPONENTS - P AR TS
25.056.004.010
ISSUE 0 6-93
Page 79
IM 25.055AC UA (C/6-01)
69
AAA7130 V ACUUM DIFFERENTIAL REGULATING VALVE - PAR TS
25.056.003.010A
ISSUE 0 05-00
NOTE: FOR P ARTS LIST, SEE DWG. 25.056.003.010B.
Page 80
IM 25.055AC UA (C/6-01)
70
AAA7130 VACUUM DIFFERENTIAL REGULATING VALVE - PARTS LIST
25.056.003.010B
ISSUE 0 05-00
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
Page 81
IM 25.055AC UA (C/6-01)
71
U25762 SMALL THROA T
U25763 LARGE THROAT
2" INJECTOR - PARTS
With Pressure-Operated Plug Shut-Off
25.052.001.046A
ISSUE 0 10-95
NOTE: FOR P ARTS LIST, SEE DWG. 25.052.001.046B.
Page 82
IM 25.055AC UA (C/6-01)
72
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
U25762 SMALL THROA T
U25763 LARGE THROAT
2" INJECTOR - PARTS LIST
With Pressure-Operated Plug Shut-Off
25.052.001.046B
ISSUE 0 10-95
Page 83
IM 25.055AC UA (C/6-01)
73
NOTE: FOR PAR TS LIST , SEE DWG. 25.052.001.051B.
U25764 SMALL THROA T
U25765 LARGE THROAT
2" INJECTOR - PARTS
With Manually Operated Plug Shut-Off
25.052.001.051A
ISSUE 6 05-00
Page 84
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74
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
U25764 SMALL THROAT; U25765 LARGE THROAT
2" INJECTOR - PARTS LIST
With Manually Operated Plug Shut-Off
25.052.001.051B
ISSUE 0 05-00
.ONYEK.ONTRAP.YTQNOITPIRCSED
194504AXP1 46752UNIDESU-TAORHTLLAMS-YAWLIAT
RO
05504AXP1 56752UNIDESU-TAORHTEGRAL-YAWLIAT 296543P1EGNALF 392314P3 DO"2/1-2xDI"4/1-2,N-ANUB,)822(GNIR-O 435504AXP1 46752UNIDESU-TAORHTLLAMS
RO
45504AXP1 56752UNIDESU-TAORHTEGRAL 574504P1 46752UNIDESU-TAORHTLLAMS-GULP
RO
84504P1 56752UNIDESU-TAORHTEGRAL-GULP 623604AXP1 CYOLLETSAH,REHSAW"61/9 795504P1DORGULP 836122U1TELNIEET 920713P1 DO"61/9xDI"8/3,N-ANUB,)011(GNIR-O
0139804P1ETALP
1191601P1 61-"4/3)SSARB(TUNXEH 2191391U1BONK 313785NP1 81-"61/5)SSARB(TUNPAC 4187504P1 DO"61/51-2xDI"4/3-2,N-ANUB,)841(GNIR-O 5141715P1GNIRPS 6108502U1 TSOP&REDLOHMETS 7122862BXP1 DO"1xDI"4/3,NOLFET,)012(GNIR-O 8152274P1METS 9147335P1YDOBTELNI 0255504P1REVOC
1226233BP2 )SSARB(REHSAW"2/1 226866BP2 31-2/1)SSARB(TUN.XEH 3268205P1TEKSAGGNIR 4294671P21.GL"4/3-1x61-8/3)LENOM,.DH.XEH(TLOB 5200183P42)LENOM(REHSAW"8/3 6234561P2161-8/3)LENOM(TUN.XEH 7288443P2GNIKCABCSID 8278443P2LAESTEKSAG 9223134P1 WERCSMGARHPAID 0333134P1 TUNMGARHPAID
1371734P1MGARHPAID 2314324P1 RENIATERGNIR-O 3329804P2DUTS 4309804AXP1GNIHSUB 5331293P2TUNNOINU 6333293P1 THGIARTSNOINUFLAH 7353293P1 WOBLENOINUFLAH 83464405PR2GNIBUT
Page 85
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75
U19315 INJECTOR SHUT-OFF UNIT - PARTS
25.100.06.111
ISSUE 6 2-93
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
Page 86
IM 25.055AC UA (C/6-01)
76
AAA4316 1” STANDARD INJECTOR - PARTS
25.200.002.030A
ISSUE 0 10-95
NOTE: FOR PAR TS LIST, SEE DWG. 25.200.002.030B.
Page 87
IM 25.055AC UA (C/6-01)
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WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
AAA4316 1” STANDARD INJECTOR - PARTS LIST
25.200.002.030B
ISSUE 0 10-95
Page 88
IM 25.055AC UA (C/6-01)
78
JUNCTION BOX - PARTS
25.055.000.017A
ISSUE 0 6-97
NOTE: FOR P AR TS LIST, SEE DWG. 25.055.000.017B.
Page 89
IM 25.055AC UA (C/6-01)
79
JUNCTION BOX - PARTS LIST
25.055.000.017B
ISSUE 0 6-97
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
.ONYEK.ON.TRAP.YTQNOITPIRCSED
14709AAA1 LIATEDLENAPDNAERUSOLCNE 278952U2KCOLBLANIMRET 33041BAA1PIRTSREKRAM 487106P1PIRTSREKRAM 533734P8WERCS.GL"8/5x23-6 605405P1 NOITCENNOCDNUORG 720181P1 KL,REHSAWLENOM"4/1 839692P1 .GL"2/1x02-4/1,TOLSDH,.DR,.HCAM,WERCS 976544P1 02-4/1TUNXEHMAJSS
0102213P.NI21NEERGERIW.AG61#
1129463P1GULLANIMRET 2166973P1GULLANIMRET 3137106P1LEBALGNINRAW
Page 90
IM 25.055AC UA (C/6-01)
80
AAA4313 1” ANTI-SYPHON INJECTOR - PARTS
25.200.002.040A
ISSUE 0 10-95
NOTE: FOR PAR TS LIST, SEE DWG. 25.200.002.040B.
Page 91
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81
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
AAA4313 1” ANTI-SYPHON INJECTOR - PARTS LIST
25.200.002.040B
ISSUE 0 10-95
Page 92
IM 25.055AC UA (C/6-01)
82
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
PLASTIC 1” FIXED THROAT INJECTOR AND TAILWA Y DETAILS - PARTS
25.200.003.010A
ISSUE 0 10-95
● SOLUTION HOSE MA Y BE CONNECTED DIRECTL Y TO THE INJECT OR T AIL W A Y. IF RIGID PVC PIPE IS USED, A PIECE OF STRAIGHT PIPE A T LEAST EIGHT INCHES LONG SHOULD BE COUPLED TO THE END OF THE INJECTOR T AIL W AY BEFORE ANY ELBOWS, TEES, OR SIMILAR FLOW RESTRICTIONS ARE USED. THIS IS TO PREVENT ANY FLOW DISTURBANCES THA T COULD AFFECT THE HYDRAULIC PERFORMANCE OF T AIL WAY CONNECTIONS.
NOTE: SIZE NUMBER STAMPED ON THROAT . LETTER DESIGNATION STAMPED ON T AILPIECE.
WHEN REORDERING O-RINGS MARKED ❏ SPECIFY U21275 FOR P AIR. NOT SOLD SEPARATEL Y.
Page 93
IM 25.055AC UA (C/6-01)
83
ASSEMBL Y NOTES: ASSEMBLE THROAT, TWO O-RINGS, AND TAILPIECE AS SHOWN, BEFORE INSERTING IN
INJECTOR BODY.
ORDERING INFORMATION:
X STANDARD COMBINA TION WHEN HYDRAULIC CONDITIONS PERMIT. O NON-STANDARD COMBINA TION, MAY BE USED IF REQUIRED.
IF NO SYMBOL IS INDICA TED, COMBINA TION CANNOT BE USED.
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
PLASTIC 1” FIXED THROAT INJECTOR AND TAILWAY DET AILS - PARTS LIST
25.200.003.010B
ISSUE 0 10-95
Page 94
IM 25.055AC UA (C/6-01)
84
AAA4310 3/4” STANDARD INJECTOR - PARTS
25.200.002.010A
ISSUE 0 10-95
NOTE: FOR PARTS LIST, SEE DWG. 25.200.002.010B.
Page 95
IM 25.055AC UA (C/6-01)
85
AAA4310 3/4” STANDARD INJECTOR - PARTS LIST
25.200.002.010B
ISSUE 2 7-99
.ONYEK.ONTRAP.YTQNOITPIRCSED
17451AAA1 TPN"4/1TAESTEPPOP/TELNI 223314AXP1 DO"61/3-1xDI"1,NOTIV)021(GNIR-O 397259P1TEPPOP,GNIR-O 423079P1TEPPOP 555684P1 .KCTEPPOP,GNIRPS 659213P1TPN4/1,GULP 73374HDA1LEBALNOITUAC 843079P1METS 97804BAA1TAESEVLAV
0146179P1TUNNOINU 1192749P1GNIR-O 210904BAA1TUN
12)ELBATEES(1YAWLIAT 2267984P1 DETAOCRANYK,GNIRPS 3227969P1YDOBREWOL 4290472AXP2 DO"4/3xDI"61/9)311(GNIR-O 5228462AXP1 KCEHC.HPAID,GNIR-O
72)ELBATEES(1ELZZON 8236079P1MGARHPAID
1324379P1NOTIV,GNIR-O 2337969P1YDOBREPPU 335234AAA1 NOTIV,MGARHPAID
YAWLIAT)12(EDOCELZZON)72(.ONEZIS
26984BXPB 16984CXP07 26984CXPC 16984DXP48 26984DXPD 16984EXP99 26984EXPE 16984FXP021 26984FXPF 16984GXP041 26984GXPG 16984HXP561 26984HXPH 16984JXP391
26984JXPJ 16984KXP242
26984SXPS
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
Page 96
IM 25.055AC UA (C/6-01)
86
AAA4307 3/4” ANTI-SYPHON INJECTOR - PARTS
25.200.002.020A
ISSUE 2 6-01
NOTE: FOR PAR TS LIST, SEE DWG. 25.200.002.020B.
Page 97
IM 25.055AC UA (C/6-01)
87
AAA4307 3/4” ANTI-SYPHON INJECTOR - PARTS LIST
25.200.002.020B
ISSUE 3 6-01
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
YAWLIAT)12(EDOC
26984BXPB 26984CXPC 26984DXPD 26984EXPE 26984FXPF 26984GXPG 26984HXPH
26984JXPJ
26984SXPS
ELZZON)72(#EZIS
24094CXP07 24094DXP48 24094EXP99 24094FXP021 24094GXP041
24094HXP561 24094JXP391 24094KXP242
.ONYEK.ONTRAP.YTQNOITPIRCSED
17451AAA1 TPN"4/1TAESTEPPOP/TELNI 223314AXP1 DO"61/3-1xDI"1,NOTIV)021(GNIR-O 397259P1TEPPOP,GNIR-O 423079P1TEPPOP 555684P1EVLAV.KC,GNIRPS 659213P1TPN"4/1,CVP,GULP 73374HDA1LEBALNOITUAC 843079P1METSEVLAV 97804BAA1TAESEVLAV
0146179P2TUNNOINU 1192749P2GNIR-O 210904BAA2TUN 3153079P2NIPEDIUG 4183079P1TEKCARB 51871001P26M,WERCS 7100952AXP2 DO"8/3xDI"4/1,NOTIV)010(GNIR-O 8160025P2REHSAW 9173079P1ETALPGNIKCAB 0274833P2 .GL"23/91x63-4#)REVLIS(WERCS.HCAM
12)WOLEBELBATEES(1YAWLIAT 2256079P1GNIRPS 4290472AXP2 DO"4/3xDI"61/9,NOTIV)311(GNIR-O 5254362AXP2 DO"61/11xDI"2/1,NOTIV)211(GNIR-O 6263079P1PACDNE
72)WOLEBELBATEES(1ELZZON 8236079P3MGARHPAID 9285079P1YDOBELDDIM 0367984P1 )DETAOCRANYK(GNIRPS 1324379P1NOTIV,GNIR-O 2337969P1YDOBREPPU 335234AAA1NOTIV,MGARHPAID 4304004AXP1 DO"61/1-1xDI"8/7,NOTIV)811(GNIR-O
Page 98
IM 25.055AC UA (C/6-01)
88
MAIN CONNECTION - PARTS
For Hose
50.845.02.011
ISSUE 6 2-82
NOTE: ✴ DOES NOT INCLUDE CORPORATION COCK. ORDER SEPARATELY, SPECIFYING PIPE
THREAD.
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
Page 99
IM 25.055AC UA (C/6-01)
89
PLASTIC MAIN CONNECTION - PARTS
For 3/4” Or 1” Solution Lines With 1” Corporation Cock
50.845.06.011
ISSUE 14 2-93
NOTE: ✴ P AR T OF SOLUTION TUBE U26131. ▲ P ART OF CORPORATION COCK U617 OR U638. WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR DAMAGE TO EQUIPMENT, DO NOT EXCEED
WORKING PRESSURE OF HOSE OR FLEXIBLE PLASTIC PIPE. NEVER EXCEED 125 PSI A T 70° F. USE RIGID PIPE BETWEEN DISCHARGE AND MAIN CONNECTIONS WHEN PUMPING HAZARDOUS CHEMICALS.
CAUTION: FOR PROPER DISPERSION OF SOLUTION, THE END OF THE TUBE MUST EXTEND INTO THE MAIN,
APPROXIMATELY 1/2 TO 1/3 THE DIAMETER OF THE MAIN. CUT OFF THE TUBE IF TOO LONG AND SHORTEN CHAIN AN EQUAL AMOUNT .
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
Page 100
IM 25.055AC UA (C/6-01)
90
MAIN CONNECTION - PARTS
For 1-1/2” Solution Line
50.845.006.021
ISSUE 12 9-92
WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR DAMAGE TO EQUIPMENT, DO NOT EXCEED
WORKING PRESSURE OF HOSE OR FLEXIBLE PLASTIC PIPE. NEVER EXCEED 100 PSI A T 70° F. USE RIGID PIPE BETWEEN DISCHARGE AND MAIN CONNECTIONS WHEN PUMPING HAZARDOUS CHEMICALS.
CAUTION: FOR PROPER DISPERSION OF SOLUTION, THE END OF THE TUBE MUST EXTEND INTO THE MAIN,
APPROXIMATELY 1/2 TO 1/3 THE DIAMETER OF THE MAIN. CUT OFF THE TUBE IF TOO LONG.
WHEN ORDERING MA TERIAL, ALW A YS SPECIFY MODEL AND SERIAL NUMBER OF APP ARA TUS.
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