Instruction Manual Series 70CV2000 Chloromatic TM Valve used with Series & FX5500 Gas Dispensing Systems

Transcription

1 Instruction Manual Series 70CV2000 Chloromatic TM Valve used with Series & FX5500 Gas Dispensing Systems

2 These instructions describe the installation, operation and maintenance of the subject equipment. Failure to strictly follow these instructions can lead to an equipment rupture that may cause significant property damage, severe personal injury and even death. If you do not understand these instructions, please call De Nora Water Technologies for clarification before commencing any work at and ask for a Field Service Manager. De Nora Water Technologies, Inc. reserves the rights to make engineering refinements that may not be described herein. It is the responsibility of the installer to contact De Nora Water Technologies, Inc. for information that cannot be answered specifically by these instructions. Any customer request to alter or reduce the design safeguards incorporated into De Nora Water Technologies equipment is conditioned on the customer absolving De Nora Water Technologies from any consequences of such a decision. De Nora Water Technologies has developed the recommended installation, operating and maintenance procedures with careful attention to safety. In addition to instruction/operating manuals, all instructions given on labels or attached tags should be followed. Regardless of these efforts, it is not possible to eliminate all hazards from the equipment or foresee every possible hazard that may occur. It is the responsibility of the installer to ensure that the recommended installation instructions are followed. It is the responsibility of the user to ensure that the recommended operating and maintenance instructions are followed. De Nora Water Technologies, Inc. cannot be responsible deviations from the recommended instructions that may result in a hazardous or unsafe condition. De Nora Water Technologies, Inc. cannot be responsible for the overall system design of which our equipment may be an integral part of or any unauthorized modifications to the equipment made by any party other that De Nora Water Technologies, Inc. De Nora Water Technologies, Inc. takes all reasonable precautions in packaging the equipment to prevent shipping damage. Carefully inspect each item and report damages immediately to the shipping agent involved for equipment shipped F.O.B. Colmar or to De Nora Water Technologies for equipment shipped F.O.B Jobsite. Do not install damaged equipment. De Nora Water Technologies, COLMAR OPERATIONS COLMAR, PENNSYLVANIA, USA IS ISO 9001: 2008 CERTIFIED

3 General The Series 70CV2000 Chloromatic TM valve used inside the Gas Dispensing Cabinet is a variation of the valve discussed in Instruction Bulletin When the Chloromatic valve is used in the gas dispenser cabinet, the valve is mounted at the top as shown in Figure 1. The Chloromatic valve is factory installed, wired and tested in the cabinet prior to shipment, therefore there is no installation requirement. This addendum contains retransmission and alarm options for which wiring diagrams are included. Also included is a wiring diagram and discussion regarding the optional hand-automatic station (no customer wiring is required if factory installed). Gas Flow Capacity The gas flow capacity of the Series & FX5500 gas dispensing systems is given in Table A. Gas flow capacities to 500 lb/d (chlorine), use the smaller valve shown in Instruction Bulletin The valve used for the higher capacities of the & FX5500 systems are shown in Figure 2. Two different tube assemblies, depending upon capacity, are available as shown. Figure 1 - Component Identification Table A Flow Ranges Ammonia (NH3) Chlorine (CL 2 ), Sulfur Dioxide (SO 2 ) lb/d kg/h lb/d kg/h

4 Figure 2 - Exploded View of Gas Valve

5 1 OPTIONAL FEATURES (Not discussed in Instruction Bulletin ) 1.1 Retransmission Additional circuits, on the option circuit board, provide for retransmission of a 4-20 ma dc signal that is directly proportional to the gas flow rate. In order to prevent transmission of false signals, the retransmission signal is interlocked with two vacuum switches. One switch measures the vacuum created by the ejector while the other switch measures the vacuum in the line going to the vacuum regulator. Either a loss of ejector vacuum (low vacuum) or an empty gas container(s) (high vacuum) will open a contact to break the retransmission circuit. If either switch opens, a 4 ma current will be retransmitted regardless of valve position. The additional customer wiring required for this feature is shown in Figure 3. This wiring is in addition to the basic wiring shown in Instruction Bulletin The retransmission output connects to the RO terminal on the option circuit board and returns to the COM terminal on the main circuit board. A load between 0 and 800 ohms is permissible. Avoid running the signal lines in the same conduit as the power lines. The vacuum switches are factory installed in the cabinet and wired by Capital Controls Company Inc. Figure 5A shows the wiring diagram for future troubleshooting purposes. The same vacuum switches are used for the optional alarms and are discussed in section II that follows. See section titled Functional Description for details regarding the electronic circuits used for retransmission. 1.2 Alarms Vacuum switches may be furnished to provide an electrical alarm contact. Note: if the retransmission option is selected, the same vacuum switches are used for dual purposes (see section I, preceding). Alarms are defined as follows and either one or both may be furnished. 1. Loss of vacuum (low vacuum). This switch monitors the vacuum produced by the ejector. The loss of water to the ejector or a disconnected gas line could result in a loss of vacuum causing the alarm contacts to close. 2. Excess vacuum (high vacuum). This switch monitors the gas cylinder or container. The closing of the shut-off valve at the cylinder or an empty container will produce a high vacuum. Either action will cause the alarm contacts to close. Figure 3 shows the additional customer wiring required if the alarm option is specified. Figure 5B shows the factory wiring of these switches for future troubleshooting. Figure 3 - Additional Customer wiring for Retransmission and/or Alarm Output

6 1.3 Hand-Auto Station Operation of the Chloromatic Valve in the Series & FX5500 gas dispensing systems is identical to that discussed in Instruction Bulletin The dosage adjustment (with its on-off power switch) and the 3-position 1, D, 2 switch (optional) are mounted on the valve case. The optional hand-auto station mounted on the cabinet is used by the operator to select either the manual or automatic mode of operation. Figure 4 shows the legend plate of this station, which is mounted on the face of the cabinet, to aid in its understanding. If the manual mode is selected, the valve motor is inoperative and will stay in the last position selected. To change gas flow through the valve, the operator turns the 3-position switch to either (+) or (-). The switch is spring returned to its normal or center off position. As long as the switch is held in the (+) or (-) position, the valve motor is running. It takes approximately seconds for the valve to run full scale. From the front of the cabinet, one can observe the flowmeter reading as an indication of valve position. If the switch is held in the (+) position, the valve moves open. In the (-) position, the valve moves shut. If the automatic mode is selected, the valve is automatically positioned as directed by the input signal(s). In the automatic mode, the (+) and (-) switch positions are inoperative. This hand-auto station is factory installed and wired. Figure 5A shows the wiring diagram used for installation, for future troubleshooting purposes only. Figure 4 - Legend Plate for Hand-Auto Switch

7 2 FUNCTIONAL DESCRIPTION 2.1 Retransmission Option The retransmission signal is taken directly from the feedback potentiometer buffer and is converted from a voltage to a current. Adjustments are provided for zero and span. The current signal provides direct output for customer use and an adjustable current limit. The V/I converter functions by balancing the feedback voltage and an intermediate voltage signal (which is generated by an intermediate current). Pins 5, 6 & 7 of amplifier U201B receive the summation of the feedback signal through resistor R218 and zero adjust potentiometer R220 through R 219. This signal is balanced against the intermediate feedback voltage on the wiper of the span adjustment R225. Span and zero potentiometers are adjusted so that a 5 V drop occurs across R224 for a 20 ma output and a 1 V drop at 4 ma output. The amplifier U201B and Q201 serve the function of shifting signal level to the +24 V supply. Amplifier U201C (pins 8, 9 & 10) is used to drive the output transistor, Q203. The intermediate voltage signal of R224 on pin 9 is matched at pin 10 by the voltage drop across R227 (negative feedback signal). This voltage drop is the result of current drawn by R236 and Q203. Current limiting is provided through FET transistor Q202, R230 and the limit adjustment potentiometer R231. The limit potentiometer is adjusted so that Q202 begins shutting off when more than 4 ma attempts to pass through the limit circuit. Externally mounted vacuum switches are used with the retransmission option. The switches are wired in series and connect across terminals TB & 16. The switch contacts are closed when there is: - Gas in the cylinder and - Water to the ejector to create sufficient vacuum Under this condition, current will flow to the RO terminal as dictated by the feedback potentiometer through the V/I converter. If either vacuum switch opens, only the 4 ma allowed by the current limit circuit can flow to the RO terminal. Note: resistors R221 and R228 are inserted if the retransmission circuit is omitted. The resistors prevent the amplifiers from oscillating and disturbing the other amplifiers. 2.2 Alarm Option The alarm option consists of either one or two vacuum switches, as specified. The switches are mounted within an enclosure which has a terminal barrier strip for customer connection of the alarm(s). If retransmission was also specified, the switches serve a dual function where the other set of contacts are used as discussed in paragraph 1.1. All piping and wiring required for the alarm(s) is completed by the factory. No adjustments are required. 2.3 Hand-Automatic Station The hand-automatic station consists of two switches that mount on the face of the cabinet. The upper 2-position switch selects the automatic or hand mode of operation. The lower 3-position switch is operative in the hand mode and is used to operate the valve motor. With the switch held in the (+) position, the open winding of the valve motor is energized. Conversely, with the switch in the (-) position, the close winding of the motor is energized. If the 2-position switch is placed in the automatic mode, the (+) (-) switch is deactivated. Here, the signals from the motor logic and motor drive sections operate the motor

8 Figure 5A - Modifications & Additional Wiring

9 3 MAINTENANCE It is recommended that the Gas Dispensing System be inspected and serviced a minimum of once per year. More frequent service periods may be required due to: 1) the type, quality and quantity of the gas being handled, 2) the complexity of the gas supply system and 3) operation procedures. More frequent service periods are especially indicated when venting of the VR is occurring during the one year operational period. This is usually indicative of foreign debris holding the inlet valve open or destruction of the inlet valve parts caused by the gas quality not up to industry purity standards. 3.1 General The gas valve used for the & FX5500 gas dispensing systems is different from the one shown in the Chloromatic Instruction Bulletin Figure 2 in this bulletin shows the valve used with this system (which is actually a part of the piping system). As such, the Chloromatic Valve cannot be assembled as a separate unit, but must be assembled into the dispenser cabinet as separate pieces and sub-assemblies. 3.2 Assembly For discussion purposes, it is assumed that the valve operator is a completed sub-assembly, the gas valve is ready to be assembled into the gas dispenser cabinet, and the signal for 50% flow has been recorded. Proceed as follows: 1. Using the manual control knob, position the lead screw so that its end is accessible through the slot in the rear wall of the valve support casting. 2. Place the wiper seal and then the spring-loaded seal over the plastic end and onto the valve exten sion. Assemble the lock nut on the stem. Thread the stem into the extender to obtain the 3/8 inch dimension shown in Figure 2. Tighten the lock nut securely. Pass the stem and valve extension through the lower support housing. Press the spring-loaded seal and wiper seal into the housing seal s counter bore. Slide the wiper seal O ring over the valve extension and press it into the counterbore. Applying a very thin film of lubricant (P/N 140B001U01) to the O ring will make the assembly easier. 3. Assemble the orifice plug assembly to the stem making sure the spring clip is properly engaged. 4. Mount the assembly from steps 2 and 3 to the support casting with the three hex head cap screws. In doing this, the valve extension will slide onto the lead screw. Torque the hex head cap screws evenly to approximately 15 inch-pounds. 5. Position the valve extension so that there is approximately 1/16 inch clearance between the shoul der on the lead screw and the end of the brass bushing. Tighten the set screw. 6. Place the two tube seal O rings, properly lubricated, into the grooves in the top of the lower support housing. 7. Place either the low or high capacity tube assembly into the lower support housing. Guide the upper end of the orifice plug assembly through the hole in the outlet adapter. Note that the low capacity tube has two additional O rings used to seal the tube to the inlet adapter. These O rings should be lightly coated with lubricant before installation. 8. Lower the tube shield over the metering tube and tighten the lower coupling nut complete the valve assembly. 9. With the upper coupling nut and O ring in place, lower the upper support housing onto the tube shield. Tighten the coupling nut to complete the valve assembly. 10. Adjust the flow to 50%, then loosen valve extension set screw and change input signal to match value recorded before disassembly. Tighten set screw and reconnect signal wiring as necessary. For further assistance, see Instruction Bulletin

10 Figure 5B - Additional Wiring for Alarms Design improvements may be made without notice. Represented by: De Nora Water Technologies 3000 Advance Lane Colmar, PA ph fax web: mail: info.dnwt@denora.com SEP Registered Trademark All Rights Reserved.