PROJECT OPERATING MANUAL: DATE: 08/12/10 DISTRIBUTOR: ATLANTIC PUMP & ENGINEERING INC. PURCHASE ORDER #:

Transcription

1 1 GENERAL INFORMATION PROMINENT WARRANTY START-UP & INSTALLATION GUIDELINES PUMP SELECTION TIPS TROUBLESHOOTING GUIDELINES PROJECT OPERATING MANUAL: DATE: 08/12/10 DISTRIBUTOR: ATLANTIC PUMP & ENGINEERING INC. PURCHASE ORDER #: PROJECT NAME: AWD/LWD LAKE Aub. PUMP STATION EQUIPMENT: P2_S1CA_CPVC_SODIUM HYPO DOSING SKID W/2- PUMP NON-GFI TERM BOX KIT (1) SPARE PARTS KIT SODIUM HYPO CHEMICAL METERING PUMP SIGMA 1 IDENT: S1CAH12035PVT0070UDC100C MOTORIZED METERING PUMP SIGMA 1 S1CAH SPARE PARTS KIT PROMINENT 15FT CONTROL CABLES SODIUM HYPO PIPING COMPONENTS ACCUDRAW PVC CALIBRATION COLUMN ASAHI CPVC/VITON TYPE 21 VENTED BALL VALVES BLACOH CPVC/VITON PULSATION DAMPENERS HAYWARD CPVC Y-STRAINER CPVC/PTFE BACKPRESSURE & PRESSURE RELIEF VALVES PRECISION SS GAUGE & BLACOH CPVC ISOLATOR SEAL SPEARS SCH.80 CPVC PIPING & FITTINGS MECHANICAL DWGS. MECHANICAL GENERAL ARRANGEMENT DWG A ELECTRICAL DWGS. ELECTRICAL GENERAL ARRANGEMENT DWG B PUMP NON GFI TERM BOX KIT E PUMP TERM BOX DWG. MAINTENANCE SUMMARY FORMS MAINTENANCE SUMMARY FORM RECOMMENDED SPARE PARTS SUMMARY FORM MAINTENANCE & LUBRICATION FORM TESTING & QUALITY ASSURANCE REPORTS SYSTEMS MECHANICAL FINAL INSPECTION REPORT SYSTEMS HYDROSTATIC FINAL INSPECTION REPORT

2 CDM CONSTRUCTORS, INC. AWD/LWD LAKE AUB. PUMP STATION PROJECT Operating Manual Documents for SODIUM HYPOCHLORITE DOSING SYSTEM Specification Section SODIUM HYPOCHLORITE FEED SYSTEM ProMinent Fluid Controls, Inc. 136 Industry Drive Pittsburgh, PA 15275

3 MECHANICAL EQUIPMENT CHEMICAL METERING PUMP EQUIPMENT SODIUM HYPOCHLORITE DOSING SYSTEM PROJECT TITLE: AWD/LWD LAKE AUB. PUMP STATION PROJECT SPEC. SECTION: CONTRACTOR: CDM CONSTRUCTORS, INC. 25 INDUSTRIAL AVENUE CHELMSFORD, MA CONTACT: ERIN MARGOLIUS PHONE: FAX: MANUFACTURER: PROMINENT FLUID CONTROLS INC. RIDC PARK WEST 136 INDUSTRY DRIVE PITTSBURGH, PA CONTACT: KEVIN POINTER PHONE: FAX: LOCAL REP: ATLANTIC PUMP & ENGINEERING INC. PO BOX 110 SANFORD, ME CONTACT: TARAD NADEAU PHONE: FAX:

4 ProMinent Warranty 1) WARRANTY, REMEDY, DISCLAIMER: The warranties set out in this clause shall be conditional upon fulfillment of the Purchaser's contractual obligations, including all terms of payment. For sales of completed pumps and controllers, the warranty shall be conditional upon the Purchaser completing and returning the attached Warranty Validation Card. Seller warrants that the Drive Units and DULCOMETER Controllers will be of good workmanship and material for two (2) years from the date of purchase by owner of new equipment from an authorized distributor of manufacturer, but no longer than two and one-half (2-1/2) years from the date of shipment by manufacturer. All Dulcotest sensors are warranted for (6) months from the date of shipment by manufacturer. For sales of liquid ends, Bello Zon, Bono Zon, pump accessories, standard engineered products, custom designed items and items not manufactured by ProMinent, Seller warrants that the products will be of good workmanship and material for one (1) year from the date the goods are shipped by Seller. If purchaser claims that the goods are defective, he must permit Seller's personnel at Seller's option to inspect the goods on Purchaser's property. Purchaser shall not return the goods to Seller unless Purchaser obtains prior written approval of such from Seller. If, after inspection, Seller determines that the goods are defective, Seller will repair or replace goods at Seller's option and at Seller's cost. THIS WAR- RANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED AND STATUTORY INCLUDING THE WARRANTIES OF FITNESS FOR PURPOSE AND MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. The warranty provided for herein shall not apply to any goods that become defective for the following reason: (a) unsuitable or unreasonable use (b) faulty assembly, installation or servicing by the Purchaser or any third party (c) faulty or careless handling ProMinent 2) DISCLAIMER OF TORT LIABILITY: PURCHASER SPECIFICALLY UNDERSTANDS AND AGREES THAT SELLER SHALL NOT BE LIABLE IN TORT, WHETHER BASED ON NEGLIGENCE, STRICT LIABILITY OR ANY OTHER THEORY OF TORT LIABILITY, FOR ANY ACTION OR FAILURE TO ACT IN RESPECT TO THE MANUFACTURE, PREPARATION FOR SALE, OR DELIVERY OF THE GOODS. IT IS THE PARTIES' INTENT AND THE INTENT OF THIS PARAGRAPH TO ABSOLVE AND PROTECT SELLER FROM ANY AND ALL TORT LIABILITY. 3) EXCLUSIVE REMEDY: PURCHASER SPECIFICALLY UNDERSTANDS AND AGREES THAT PURCHASER'S SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY, TORTIOUS CONDUCT OR ANY OTHER CAUSE OF ACTION AGAINST SELLER SHALL BE THE REMEDY PROVIDED IN PARA- GRAPH TWO (2) ABOVE. 4) EXCLUSION OF CONSEQUENTIAL DAMAGES: PURCHASER SPECIFICALLY UNDERSTANDS AND AGREES THAT UNDER NO CIRCUMSTANCES WILL SELLER BE LIABLE TO PURCHASER FOR ECONOMIC, SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LOSSES OF ANY KIND WHAT- SOEVER, INCLUDING BUT NOT LIMITED TO, LOSS OF ANTICIPATED PROFITS AND ANY OTHER LOSS CAUSED BY REASON OF THE NON-OPERATION OF THE GOODS. THIS EXCLUSION IS APPLICABLE TO CLAIMS FOR BREACH OF WARRANTY, TORTIOUS CONDUCT OR ANY OTHER CAUSE OF ACTION AGAINST SELLER. 5) ALL TERMS AND CONDITIONS OF SALE CONTAINED IN SELLER'S ACKNOWLEDGMENT/OFFER TO SELL APPLY AND ARE IN NO WAY ALTERED BY THIS WARRANTY VALIDATION CARD. ProMinent Fluid Controls RIDC Park West 136 Industry Drive Pittsburgh, PA (412) general 21

5 2. The skid may have been jarred during shipping. Inspect equipment and shipping container for damage before accepting delivery. Make note on the carrier s bill-of-lading the extent of the damage, if any, and notify the carrier. Save the shipping container until your system is started up. 3. Store equipment on firm level surface in original packing container. Do not store equipment where it may be exposed to extreme temperatures, precipitation, humidity, or dust. Avoid direct sunlight that could overheat and damage equipment. WARNING PUMPS MAY BE FILLED WITH OIL WHICH COULD LEAK IF TILTED Temperature: 14 F to 120 F Air humidity: max. 95% relative humidity, non-condensing QS delivery B-001.doc!!! IMPORTANT PLEASE READ!!! ProMinent SYSTEMS SITE DELIVERY AND STORAGE CHECKLIST 1. Check packing list for completeness and note any missing items immediately. Ambient Conditions for storage and transport: Please call if you have questions. ProMinent Fluid Controls, Inc. RIDC Park West 136 Industry Drive Pittsburgh, PA Phone: (412) Fax: (412)

6 1. Mount equipment on hard flat level surface. Stainless steel or FRP angle may be used to fasten skids down. 2. Do not install equipment in areas of extreme heat, cold, dust or humidity. Avoid areas where objects or fluids can drop from overhead. 3. Install piping so connections properly meet skid termination points. Do not stretch field installed piping to meet skid termination points. Stressed plastic piping will fail! 4. Check the tightness on all unions. Hand tighten only - no tools. Unions incorporate an o-ring seal. Ensure that the o-ring is seated properly before tightening. 6. Allow provisions for draining the system piping. Skid components will require maintenance. Ensure that chemicals can be evacuated from skid piping and components. 7. Do not down-size piping to or from system. Piping should be at least equal in diameter to piping on skid and one or two sizes larger for long runs. 9. Avoid getting dirt in piping during installation. Plug ends of piping with rags if construction activities are underway. All debris must be flushed from piping before system start-up. QS pre-install B-001.doc!!! IMPORTANT PLEASE READ!!! ProMinent SYSTEMS PRE-INSTALLATION CHECKLIST 5. Check the piping for breakage. The skid may have been jarred during shipping. 8. Install suction line strainer if one was not included with your packaged system 10. Check electrical connections to be sure proper voltage is supplied to unit. Please call if you have questions. ProMinent Fluid Controls, Inc. RIDC Park West 136 Industry Drive Pittsburgh, PA Phone: (412) Fax: (412)

7 !!! IMPORTANT PLEASE READ!!! ProMinent SYSTEMS QUICK START GUIDE 1. Pressure Relief Valves and Back Pressure Valves (PRV s/bpv s) are NOT pre-adjusted. ProMinent adjusts valves for QC purposes, but valves must be opened before shipping to allow water to be drained out. 2. The PRV s should be set no higher than the lowest rated component typically the pump. In any case, do not exceed 150 psi with plastic piping. Tighten the PRV only with the a proper sized screwdriver or the furnished adjusting wrench. An improper adjustment tool will damage the valve adjustment screw. No extraordinary start-up procedures are required. However, the following steps are recommended. WEAR SAFETY GLASSES WHILE WORKING ON CHEMICAL FEED EQUIPMENT! a. Unions tagged with Red Tape are purposely loosened prior to shipping. Check ALL unions for tightness and insure O-ring is properly seated before tightening. DO NOT OVERTIGHTEN! Hand tighten initially, and if necessary, apply one-eighth to one-quarter turn with properly sized wrench. DO NOT OVERTIGHTEN! b. Start the pumps in manual control mode with water DO NOT APPLY SYSTEM PRESSURE. CHECK MOTOR ROTATION! (clockwise, looking down towards pump). Open oil vent, if applicable. Check for leaks. c. Check pulsation dampener fastener bolts torque and inflate dampeners before applying system pressure (~80% of System Pressure). Set BPV for at least 15 psi pressure. Set PRV for rated pressure of weakest link in system. d. Run the system in manual mode with water. Build pressure. Check for leaks! Correct all leaks before introducing chemical into the system. e. Familiarize yourself with controls, check functionality of instruments, and verify correct pump output. f. Run the system in automatic mode with water. Verify functionality of alarms and safety devices. Verify correct pump output and functionality of instruments. g. Run the system in automatic mode with chemicals. Allow system to build pressure and check for leaks. Please call if you have questions. ProMinent Fluid Controls, Inc. RIDC Park West 136 Industry Drive Pittsburgh, PA Phone: (412) Fax: (412) B-001 Quick Start Guide

8 Pump Selection, Accessories and Installation Tips WHEN SELECTING, INSTALLING AND OPERATING A PUMP AND ACCESSORIES, THE FOLLOWING GUIDELINES SHOULD BE FOLLOWED: When selecting a pump, make allowances for extra capacity and working pressure, especially if the fluid viscosity is higher than that of water (note: Capacities in manuals pertain specifically to water at fixed pressures). If in doubt about the chemical compatibility of the liquid end materials, valves, valve balls, O-rings, suction and discharge lines and accessories, refer to the Chemical Resistance List (page 8). A foot valve with ball check valve, ceramic weight and strainer facilitates... priming. prevents loss of prime. protects the liquid end against coarse impurities. Installation Tip: Must install vertically, slightly above the bottom of the tank; directly under pump taking pump maximum suction lift into account. Note: Pump capacity is effected if not installed properly or if plugged. ProMinent For varying, corrosive media, the corrosiveness of which is unknown, select the highest rated PTFE (TT) version. For abrasive fluids, or for use in the food processing industry, select the stainless steel (SS) version if compatible with the media. The site of the metering pump should be easily accessible. The metering pump should be protected against the risk of being damaged mechanically. High ambient temperatures, radiating heat and direct sunlight should be avoided, if possible. The metering pump should be provided with a power supply of its own. If connected in parallel to other equipment, the metering pump should be switched on and off by separate contacts, e.g. by relays or contactors. If the metering pump is paced externally, the maximum input pulse rate should match the maximum stroking rate. All pumps are self-priming. The suction lift varies between 5 and 20 ft. (1.5 and 6 m), depending on the pump type (refer to Technical Data). The reduced suction lift for media having a specific gravity (density) higher than 1 can be evaluated as follows: Effective Rated suction lift = suction lift, water (f) S.G. Note: Suction lift decreases with high altitude. Contact factory for pump selection. Accessories and tips... The suction line should be... as short as possible. sloping upwards to eliminate vapor pockets. The discharge line should have... a drain valve when corrosive media is to be handled. Installation Tip: Draining is achieved by means of a tee and bleed valve, or an adjustable pressure relief valve in the discharge line. Postive suction head (flooded suction) Recommended with media which tend to develop gases. Recommended with media which has high viscosity. Installation Tips: Degassing pump must be used on suction lift applications, not flooded suction. Metering pump can be located at and fed from the foot of the supply tank. A ball-check-type injection valve Prevents back flow. Installation Tip: Should be at the end of the discharge line; Teflon injection valves are not spring-loaded and must be oriented vertically into bottom of pipe for ball to seat. Note: Pumps will not give consistent results without backpressure; our injection valve provides minimum backpressure when pumping into atmosphere. Backpressure valve Adjustable spring tension on a diaphragm. Ensures accurate metering and prevents siphoning. Installation Tips: Must be in the discharge line or mounted onto the pump in the following cases: When the discharge head is negligible (open-end discharge). The metering pump discharges into a vacuum system or the positive suction head exceeds the discharge head. Note: At least 15 psig differential pressure is required to provide repeatability of metering. Pulsation dampener Bladder type cavity with pressure gauge. Required for very long discharge lines. Required when high-viscosity media are handled. Required when a smooth flow profile is required. general 1

9 ProMinent Pump Selection and Installation Tips Cont... Installation Tips: Should be as close to the pump as possible. Set pressure at 90% of discharge line pressure. No further than 12 inches from the metering pump discharge, in direction of flow. Note: Backpressure valve is required at point of injection, downstream of pulsation dampener. Consult ProMinent for verifications when discharge lines are greater than 100 feet. Pressure relief valve In form of an adjustable backpressure valve or 3-port relief valve. Protects metering pump against "dead head" (pumping against a closed valve). Installation Tip: Must be close to the pump, upstream of the backpressure valve, for system protection. Application Suggestions: Where the discharge line is hard piped. When pumping into high pressures. Where the discharge line has several check valves installed. Note: Recommended for all motor-driven pumps. Viscous fluids Require valve springs to ensure balls seat properly. Installation Tips: Should be spring-loaded for viscous media. Operation at a greater stroke length is better than operation at a higher stroking rate. The suction piping should be sized up by one pipe size and a pulsation dampener used. Select PP4/PP5 series pumps with special liquid ends for extremely high viscosities. Positive suction recommended. Calibration column Draw down, graduated cylinder. Useful for setting up metering pump to reach desired capacity. Single pump dosing package can be equipped with a self-filling calibration assembly for application where the pump is installed above the tank (eliminates chemical handling). Installation Tip: Easy to install off the suction side of the metering pump with a ball valve to isolate from the tank. APPLICATION OF PUMP ACCESSORIES FOR AN OPTIMAL METERING SYSTEM Injection valve Diaphragm-isolated pressure gauge Backpressure valve Pulsation dampener Pressure relief valve Calibration column Metering monitor Mixer Rigid suction assembly with float switch Main Pump System Redundant (backup) System general 2

10 ProMinent Pump Series mikro g/5 D 4a Pneumados beta/4 alpha gamma/4 gamma/5 beta/5 Metering Pump Selection Guide MAX. CAPACITY U.S. GPH (L/h) DRIVE/TYPE/MAX PRESSURE PSIG (BAR) 0.4 (1.5) S/P/580 (40) 3.2 (12) S/D/232 (16) 3.9 (14) A/D/232 (16) 5.0 (19) S/D/253 (17.5) 5.6 (21) M/D/145 (10) 6.0 (23) S/D/250 (17) 8.0 (30) S/D/232 (16) 8.4 (32) S/D/253 (17.5) DRIVE CODE S = Solenoid M = Motor A = Compressed air TYPE CODE P = Packed Plunger D = Diaphragm H = Hydraulic Diaphragm Note: Rated maximum pressure is usually attainable only at lower flow rates. ProMinent gamma/l Hydro/2 Simplex Meta HK Simplex EXtronic Sigma HK Hydro/2 Duplex Meta HK Duplex Vario Hydro/3 Simplex Hydro/3 Duplex Sigma HM Meta HM Simplex Sigma/3 Makro HK Simplex Makro HMH Simplex Meta HM Duplex Makro HK Duplex Makro HMH Duplex Makro HM Simplex Makro HM Duplex Makro/5 Simplex 8.4 (32) S/D/253 (17.5) 15.3 (58) M/H/928 (64) 15.6 (59) M/P/3480 (240) 15.8 (60) S/D/363 (25) (Explosion-Proof) 20 (76) M/P/4640 (320) 30.6 (116) M/H/928 (64) 31.2 (118) M/P/3480 (240) 38 (144) M/D/174 (12) 38 (144) M/H/928 (64) 76 (288) M/H/928 (64) M/D/174 (12) 111 (420) M/D/174 (12) 208 (790) M/D/174 (12) 264 (1000) M/P/4640 (320) 302 (1141) M/H/232 (16) 318 (1204) M/D/174 (12) 417 (1580) M/P/4640 (320) 602 (2282) M/H/232 (16) 636 (2408) M/D/174 (12) 658 (2490) M/D/174 (12) 1316 (4980) M/P/4640 (320) 1589 (6014) Maximum Flow Rate: U.S. GPH general 3

11 ProMinent Data required to size metering pumps and accessories Complete this data sheet and fax it to ProMinent Pittsburgh at (412) or ProMinent Canada at (519) for a review of the system hydraulics and recommendations on pump and accessory selection. Desired capacity min./max. Available power supply Working temperature min./max. Description of process fluid Concentration % Solids content % Absolute viscosity, cp Vapor pressure at working temperature Remarks (e.g. abrasive, developing gases and fumes, flammable, corrosive) GPH (l/h) V, Hz, phase F ( C) psig (bar) Suction conditions: Suction lift min./max., or Positive suction head min./max., or Pressure in chemical tank Length of suction line Size (I.D.) of suction line Number of valves and fittings in suction line Discharge conditions: Back-pressure min./max. Discharge head min./max. Negative discharge head min./max. Length of discharge line Size (I.D.) of discharge line Number of valves and fittings in discharge line ft. (m) ft. (m) psig (bar) ft. (m) in. (mm) psig (bar) ft. (m) ft. (m) ft. (m) in. (mm) System sketch general 4

12 Troubleshooting System pressure exceeds pump discharge pressure. Decrease line pressure or select higher rated pump. Blocked or partially clogged check valves. Disassemble and clean. TROUBLESHOOTING TYPICAL PROBLEMS Discharge line too long. See "Discharge Configuration" Stroke length set too low. Control cable loose or damaged ("Error" flashes). ProMinent Vapor lock: Air in suction line from offgassing fluid (sodium hypochlorite or hydrogen peroxide). See "Loss of Prime" Jumper cap missing on external input or float switch port ("Error" flashes). Tank not vented. Ensure air can enter tank. Air leak into suction line from leak at tube connection. See "Discharge Configuration" Foot valve blocked. See "Viscosity" Low tank level (Error, Minimum). Metering pumps are affected by: Pressure Viscosity Suction conditions (length, line size, configuration) Discharge conditions (length, line size, configuration) Pressure Problem: Metering pump capacities are greatly effected by pressure. Solution: Must be calibrated at your process pressure to determine capacity. Take these precautionary measures Metering pumps should not be primed against pressure (open the bleed valve on the liquid end, where available, until product appears. Ensure all connections on suction side are "leak free," especially at the foot valve. If the chemical being pumped is compatible with water, it is helpful to prime the pump with water, if possible - this will help wet the pump seals when the pump is left idle for a long time. For metering pumps with high viscosity heads or with standard liquids with light duty springs, priming will take longer. It is sometimes easier to prime the metering pump with water. Viscosity Problem: Products where viscosity increases with a decrease in temperature or aging are a potential problem for metering pumps. They can block up the foot valve and/or pump valves. Solution: The best solution is to keep the pump pumping continuously. If the pump will be off for an extended period of time it is best to FLUSH the pump head and foot valve. Tip: Where possible, install the metering pump in flooded suction (i.e. at the base of the tank). Note: Metering pumps require valve springs to ensure the valve balls seat properly. general 19

13 ProMinent Troubleshooting Cont... Loss of Prime Problem: Introduction of air on the suction side of the pump caused by missing or blocked foot valve, poor connection at suction valve and/or foot valve or pumping from an empty tank. Solution: Check fittings for air leaks, check chemical tank level. Suction Configuration 1 Size the piping/tubing no smaller than the metering pump manufacturer's specification. 2 When drawing from the top of a drum, a foot valve must be used. 3 When draining from the base of a tote/bulk tank, a strainer is recommended to prevent sediment from entering the metering pump valves. Problem: Pumping off-gassing products such as NaOCl, PAA or H 2 O 2. Solution: Try to use metering pumps with a manually adjustable bleed valve or, preferably, a self-degassing liquid end. Problem: Using teflon tape on pump valves that are sealed by O- rings can prevent the valve from seating properly in pump head and may cause the operator to overtighten the valves therby over-compressing the seals and causing leaks. Solution: Only use thread type on NPT joints where the threads are the seating mechanism. O-ring sealed joints should not have thread tape or pipe dope. Siphoning Problem: When installing a metering pump at the base of a tote/ bulk tank, the head pressure of the container will force product through the pump - siphoning. Solution: The surest way to prevent siphoning is to install a backpressure valve in the discharge line. Note: The backpressure valve will also improve the pump consistency. 4 When draining from the base of tote/bulk tank with the pump mounted mid-way up the tote/tank, a check valve should be installed (foot valve without ceramic weight). 5 As the tank level gets below the pump height, the output capacity of the metering pump will change unless a ball check valve is installed. KEEP IT SIMPLE. Discharge Configuration 1 Size pipe/tubing no smaller than the metering pump manufacturer's specification. 2 Piping/tubing should be laid out such that the entire discharge line is full of product. If there are sags in tubing, there will be air at the highest point. As the amount of air varies, so will the capacity coming out of the injection valve. 3 Where a pulsation dampener is used, the bladder pressure must be maintained. general 20

14 S1Ca ProMinent S i g m a / 1 Motor Diaphragm Metering Pumps O v e r v i e w : S i g m a / 1 Sigma/ 1 Basic Type (S1Ba) Ideal for Economical mid-range applications (see page 133 for spare parts and page 138 for control cables) The ProMinent Sigma/ 1 is a mechanically actuated diaphragm metering pump. It has a capacity range of gph ( l/h) at a max. back pressure of psi (12-4 bar). The pump capacity is adjusted by varying the stroke length (4 mm) in 1 % steps via a self locking adjusting knob. The reproducible metering accuracy is better than ±2 % providing installation has been correctly carried out, and in the stroke length range of %. (Instructions in the operating instructions manual must be followed.) The stable, corrosion resistant metal and plastic housing is rated IP 65. To facilitate adaptation of the pumps to the widest possible range of processing requirements we offer a choice of three gearbox ratios, three liquid end sizes, two liquid end materials and either contact or analogue signal (e.g. 0/4-20 ma) control options in the form of the S1Ca Sigma controller. For safety reasons, all motor driven metering pumps must be equipped with adequate protection against electrical overload. The ProMinent Sigma Basic type is a motor driven metering pump with no internal electronic control system. The ProMinent S1Ba has a number of different drive options, including the single phase AC motor or a 3 ph. motor. product overview solenoid-driven metering pumps ProMinent Sigma Controller pk_2_104 Sigma/1 Control Type (S1Ca) Different flanges are available so that customers can use their own motor to drive the pump. The ProMinent Sigma microprocessor version (standard IP 65) allows rapid and reliable adjustment to fluctuating metering requirements. The controller has the same control panel as the ProMinent gamma/ L metering pump. The microprocessor controller of the Sigma pumps, featuring the optimum combination of variable AC frequency combined with digital stroking frequency, ensures exact metering even in the lower minimum range due to individual stroke control. The individual pump functions are simply adjusted using the five programming keys. A backlit LCD indicates the current operating status, LEDs function as operation or fault indicators and fault indicator or pacing relays monitor the pump function. (see page 138) Local or remote control is possible with PROFIBUS and/or an integrated process timer. motor-driven metering pumps pump spare parts & accessories pump engineering specifications analytical instrumentation analytical sensors 4/21/ Sigma/ 1 71

15 ProMinent S i g m a / 1 Motor Diaphragm Metering Pumps Standard Modes and Functions product overview solenoid-driven metering pumps motor-driven metering pumps pump spare parts & accessories pump engineering specifications analytical instrumentation Feed rate is determined by stroke length and stroke rate. Stroke length is manually adjustable from 1 to 100% in increments of 1% via the stroke length knob. Stroke rate can be set to a maximum of 90, 170 or 200 strokes per minute (pump dependent). An illuminated LCD displays stroke length, stroke rate and an accumulative stroke counter, which can be cleared and reset. Pump capacity output is displayed in either U.S. gph or l/h, set by the operator. Output is accumulated and totalized capacity is also displayed in either U.S. gallons or litres. The i key is used to scroll information screens for stroke rate, stroke length, stroke counter, capacity and totalized capacity. Other information is available depending on control mode. Control Modes trol Modes The control modes available with the Sigma/1 include manual, external contact with pulse control (multiplier/divider), batch, or analog control. The Profibus option includes all control modes, plus fieldbus connection. In the Manual mode, stroke rate is controlled manually. The Contact external mode allows adjustments to be made externally (e.g. by means of a pulse-type water meter for proportional chemical feed). Pulse signals are fed into the contact input of the pump by an optional control cable. Each pulse from a water meter or pulse-type controller provides the pump an input to pump at the selected pulse ratio, up to the pump s maximum stroke rate. Over-stroking the pump is not possible. Standard Functions Calibrate The pump can be directly calibrated in-line to actual flow. Calibration is maintained within the stroke frequency range of 90/170/200 spm (model dependent). A warning indicator flashes when adjustments to the stroke volume are made outside the calibrated range of +/- 10%. Auxiliary Frequency An auxiliary frequency can be programmed. This default stroking rate can be enabled via the optional control cable. Flow The Sigma/1 series metering pumps will monitor their own output, with an optional adjustable flow monitor. Every fluid discharge is sensed and fed back to the electronic control circuit of the pump. If insufficient fluid is discharged for a predetermined number of strokes (up to 125), the pump automatically stops and the red LED lights. The optional fault relay changes state to issue an alarm or activate a standby pump. Call for availability. Ensure fluid fl Float Switch An optional two-stage ProMinent float switch can be plugged into the pump to monitor chemical tank levels. An early warning is issued when the allowable minimum level is reached. The pump continues to operate while the display flashes, the yellow LED lights and an optional collective fault relay changes state to issue an alarm. If the liquid level in the supply tank drops another 3/4 (20 mm), the pump automatically shuts down, the LCD displays Minim and the red LED lights. The optional fault relay remains activated. Pause The Sigma/1 series can be remotely started and stopped via a dry contact through the optional control cable. Stop The Sigma/1 can be stopped by pressing the STOP/START key without disconnecting from the power supply. Prime Priming is activated by pressing both arrow keys at the same time while the frequency display is showing. Function and Error Indicators xs Three LED lights on the pump faceplate signal operational status. The green light flashes during normal operation, and the yellow light warns of a situation that could lead to a fault (e.g. low chemical). If a fault occurs error will appear on the LCD screen and the red LED light appears. analytical sensors 72 4/21/ Sigma/ 1

16 ProMinent S i g m a / 1 Motor Diaphragm Metering Pumps Optional Modes and Functions Optional Control Modes Analog Mode With this option, the stroking rate of the Sigma/1 is directly proportional to the analog signal. For a custom range setting, the curve feature of the analog input can be selected. With this, the pump response to the analog input can be easily programmed. Contact Mode with Pulse Control on off An external panel enables optional relays to be installed on-site. product overview This feature is used to tune the pump to contact generators of any kind (e.g. pulse-type water meter or process controller), and eliminate the need for a costly external control unit. The following functions can be selected by means of the keypad. Pulse step-up (multiply) and step-down (divide) By simply entering a factor in the range, the step-up or step-down ratio is set. For example: Step-up Factor: pulse = pump strokes 10 1 pulse = 10 pump strokes Step-down Factor: pulses = 1 pump stroke pulses = 1 pump stroke Batch Mode The Batch mode is a variation of the contact operating mode. A number of strokes can be predetermined up to 65,535 strokes (whole numbers) or the feed quantity can be predetermined. The batch is then initiated by either pressing the P key on the pump face or providing a contact to the external control cable. Access Code A programmable access code to prevent unauthorized changes to settings is available as an option. Relay outputs... Fault annunciating relay For low tank level (flow switch), loss of flow (flow monitor), loss of analog signal and diaphragm failure detector, system faults and fuse/ power supply failure. Fault annunciating and Pacing relay In addition to the fault annunciating relay, a contact closure is issued with every pump stroke (contact duration 150 ms). This allows a second ProMinent metering pump to be paced synchronously, or to totalize flow with an external stroke counter ma Analog Output A 4-20 ma analog output option is available for use with pumps that operate in the manual mode or by a remote 4-20 ma analog reference signal. The 4-20 ma analog output signal is linear to pump frequency multiplied by the percentage of stroke length. The output signal is isloated and can drive up to 300 Ohms impedance. Analog output can be used for status feedback to higher level control systems for closed loop control or for monitoring chemical usage. This option is available in combination with either the fault annunciating or pacing relay. Timer Relay The optional integrated 2-week timer offers 81 programmable events. It can be set to hourly, daily, work days, weekend, weekly or two-week periods with switch-on times from 1 second to two weeks. The timer can be programmed to change operation mode, frequency and the function of two relays. All the functions can be programmed independently of one another. Up to 13 delay times can be programmed into the timer function. The range of applications exceeds that of a standard timer. Typical application is disinfection in cooling towers, process water, etc. with the ability to automatically program shock dosages or increase the concentration at a certain interval. Fieldbus connection Monitor and control remotely via a SCADA/PLC system using the profibus-dp system. Note: Relay options not available with profibus. Profibus is not field retrofittable. solenoid-driven metering pumps motor-driven metering pumps pump spare parts & accessories pump engineering specifications analytical instrumentation analytical sensors 4/21/ Sigma/ 1 73

17 ProMinent S i g m a / 1 Motor Diaphragm Metering Pumps Specifications product overview solenoid-driven metering pumps motor-driven metering pumps pump spare parts & accessories pump engineering specifications General: Maximum stroke length: Power cord: Stroke frequency control: Stroke counting: Materials of construction Housing: 0.16 (4.0 mm) 6 foot (2 m) 2 wire + ground (supplied on control versions) S1Ba: Constant speed or optional DC/SCR drive or AC inverter S1Ca: Microprocessor control version with innovative start/stop and variable speed control proportional to set frequency or external control signal. Standard on S1Ca Glass-filled Luranyl (PPE) Wetted materials of construction: Liquid End: PVDF 316 SS Suct./Dis. Connectors: PVDF 316 SS Seals: PTFE/Viton PTFE/Viton Check Balls: Ceramic SS Pressure Relief Valves: PVDF/Viton O-rings SS/Viton O-rings Drive: Cam and spring-follower (lost motion) Lubrication: Sealed grease lubricated bearings and gearing Warranty: Two years on drive, one year on liquid end. Factory testing: Each pump is tested for rated flow at maximum pressure. Industry Standard: CE approved, CSA available (standard in Canada) Diaphragm materials: PTFE faced EPDM with Nylon reinforcement and steel core Liquid end options: Polyvinylidene Fluoride (PVDF) or 316 SS, with PTFE faced Viton seals Check valves: Single ball check, PVDF and SS versions. Optional springs available (Hastelloy C4) Repeatability: When used according to the operating instructions, better than ±2% Max. fluid operating temperatures: Material Constant Short Term (Max. Backpressure) (15 max.30 psi) PVDF 149 F (65 C) 212 F (100 C) 316 SS 194 F (90 C) 248 F (120 C) Diaphragm failure indication: Optional, see accessories. Switch is N.C., opens to indicate failure. Switch rated 250 VAC, 0.3 A inductive or 0.5 A resistive; 30 VDC,1.0 A resistive. Requires minimum 21 psig (1.5 bar) backpressure on pump. N.O. switch available upon request. Includes double diaphragm leak prevention. Max. solids size in fluid: 0.3 mm Stroke length adjustment: Manual, in increments of 1%. Motorized stroke length adjustment available. Sigma/1 Basic Version Motor: See available motors in identity code analytical sensors analytical instrumentation 74 4/21/ Sigma/ 1

18 ProMinent S i g m a / 1 Motor Diaphragm Metering Pumps Specifications Sigma/1 Control Version Control Function: At stroke frequencies equal to or greater than 33%, the integral AC variable frequency drive continuously varies the motor speed in a linear response to the incoming signal. At stroke frequencies less than 33%, the motor starts and stops according to a control algorithm to provide the desired stroke frequency. In the start-stop mode the motor speed is constant at approximately 580 RPM. Enclosure rating: NEMA 3 (IP 55) Motor data: Totally enclosed, fan cooled (IP55); class F insulation; IEC frame; 1/8 HP (0.09 kw) 230 V, 3 phase (0.7 A) Relay load Fault relay only (options 1 & 3): Fault and pacing relay (options 4 & 5): Contact load: 250 VAC, 2 A, 50/60 Hz Operating life: > 200,000 switch functions Contact load: max. 24 V, AC/DC, max. 100 ma max. 50x10 6 switch 10 V, 10 ma Contact closure: 100 ms (for pacing relay) Analog output signal: max. impedance 300 W Isolated 4-20 ma output signal Profibus - DP fieldbus options: Transfer: RS Wiring: 2-wired, twisted, shielded Length: 3637 ft. (1200 m)/328 ft. (100 m) Baudrate: 9600 bits/s; 12 Mbits/s No. of participants: 32 with 127 repeaters Topology: Line Access procedure: Master/master with token ringrelay cable (optional): 6 foot (2 m) 3 wire (SPDT) 250 VAC, 2 A Pulse contact/remote pause contact: With voltage-free contact, or semiconductor sink logic control (not source logic) with a residual voltage of <700 mv. The contact load is approximately 0.5 ma at + 5 VDC. (Note: Semiconductor contacts that require >700 mv across a closed contact should not be used). product overview solenoid-driven metering pumps motor-driven metering pumps pump spare parts & accessories pump engineering specifications analytical instrumentation analytical sensors 4/21/ Sigma/ 1 75

19 ProMinent S i g m a / 1 Motor Diaphragm Metering Pumps Capacity Data Sigma/1 Basic Version Technical 60 Hz (1750 RPM) operation Max. Output Max. Max. Suction/ Shipping data: Capacity at Maximum Stroke per Suction Suction Discharge Weight Pressure Rate Stroke Lift Pressure Connector w/motor Pump Version psig (bar) U.S. (L/h) Stroke/ ml/ (water) psig (bar) DN in. (approx.) S1Ba HM GPH min. stroke ft. (m) lbs. (kg) product overview solenoid-driven metering pumps motor-driven metering pumps pump spare parts & accessories pump engineering specifications analytical instrumentation analytical sensors PVT 145 (10) 5.3 (20) (7) 14.5 (1) 10 1/2 MNPT 19.8 (9) SST 174 (12) 5.3 (20) (7) 14.5 (1) 10 3/8 FNPT 26.5 (12) PVT 145 (10) 11.1 (42) (7) 14.5 (1) 10 1/2 MNPT 19.8 (9) SST 174 (12) 11.1 (42) (7) 14.5 (1) 10 3/8 FNPT 26.5 (12) PVT 145 (10) 15.8 (60) (7) 14.5 (1) 10 1/2 MNPT 19.8 (9) SST 145 (10) 15.8 (60) (7) 14.5 (1) 10 3/8 FNPT 26.5 (12) PVT 145 (10) 6.8 (26) (6) 14.5 (1) 10 1/2 MNPT 19.8 (9) SST 145 (10) 6.8 (26) (6) 14.5 (1) 10 3/8 FNPT 26.5 (12) PVT 145 (10) 14 (53) (6) 14.5 (1) 10 1/2 MNPT 19.8 (9) SST 145 (10) 14 (53) (6) 14.5 (1) 10 3/8 FNPT 26.5 (12) PVT 102 (7) 20.6 (78) (6) 14.5 (1) 10 1/2 MNPT 19.8 (9) SST 102 (7) 20.6 (78) (6) 14.5 (1) 10 3/8 FNPT 26.5 (12) PVT 102 (7) 13.2 (50) (3) 14.5 (1) 15 3/4 MNPT 21 (9.5) SST 102 (7) 13.2 (50) (3) 14.5 (1) 15 1/2 FNPT 29.8 (13.5) PVT 58 (4) 26.7 (101) (3) 14.5 (1) 15 3/4 MNPT 21 (9.5) SST 58 (4) 26.7 (101) (3) 14.5 (1) 15 1/2 FNPT 29.8 (13.5) PVT 58 (4) 38 (144) (3) 14.5 (1) 15 3/4 MNPT 21 (9.5) SST 58 (4) 38 (144) (3) 14.5 (1) 15 1/2 FNPT 29.8 (13.5) Sigma/1 Control Version Technical 60 Hz operation Max. Output Max. Max. Suction/ Shipping data: Capacity at Maximum Stroke per Suction Suction Discharge Weight Pressure Rate Stroke Lift Pressure Connector w/motor Pump Version psig (bar) U.S. (L/h) Stroke/ ml/ (water) psig (bar) DN in. (approx.) S1Ca HM GPH min. stroke ft. (m) lbs. (kg) PVT 145 (10) 5.3 (20) (7) 14.5 (1) 10 1/2 MNPT 19.8 (9) SST 174 (12) 5.3 (20) (7) 14.5 (1) 10 3/8 FNPT 26.5 (12) PVT 145 (10) 11.1 (42) (7) 14.5 (1) 10 1/2 MNPT 19.8 (9) SST 174 (12) 11.1 (42) (7) 14.5 (1) 10 3/8 FNPT 26.5 (12) PVT 145 (10) 13.2 (50) (7) 14.5 (1) 10 1/2 MNPT 19.8 (9) SST 145 (10) 13.2 (50) (7) 14.5 (1) 10 3/8 FNPT 26.5 (12) PVT 145 (10) 6.8 (26) (6) 14.5 (1) 10 1/2 MNPT 19.8 (9) SST 145 (10) 6.8 (26) (6) 14.5 (1) 10 3/8 FNPT 26.5 (12) PVT 145 (10) 14 (53) (6) 14.5 (1) 10 1/2 MNPT 19.8 (9) SST 145 (10) 14 (53) (6) 14.5 (1) 10 3/8 FNPT 26.5 (12) PVT 102 (7) 17.2 (65) (6) 14.5 (1) 10 1/2 MNPT 19.8 (9) SST 102 (7) 17.2 (65) (6) 14.5 (1) 10 3/8 FNPT 26.5 (12) PVT 102 (7) 13.2 (50) (3) 14.5 (1) 15 3/4 MNPT 21 (9.5) SST 102 (7) 13.2 (50) (3) 14.5 (1) 15 1/2 FNPT 29.8 (13.5) PVT 58 (4) 26.7 (101) (3) 14.5 (1) 15 3/4 MNPT 21 (9.5) SST 58 (4) 26.7 (101) (3) 14.5 (1) 15 1/2 FNPT 29.8 (13.5) PVT 58 (4) 31.7 (120) (3) 14.5 (1) 15 3/4 MNPT 21 (9.5) SST 58 (4) 31.7 (120) (3) 14.5 (1) 15 1/2 FNPT 29.8 (13.5) Note: Universal control cable necessary for external Sigma control. (see page 138) Materials In Contact With Chemicals Liquid End Suction/Discharge Valve Seals/ Balls connector ball seat PVT PVDF (Polyvinylidenefluoride) PVDF (Polyvinylidenefluoride) PTFE/PTFE Ceramic SST Stainless steel Stainless steel PTFE/PTFE Stainless steel 76 4/21/ Sigma/ 1

20 S1Ca H ProMinent S i g m a / 1 Motor Diaphragm Metering Pumps I d e n t c o d e O rd e r i n g S y s t e m ( S 1 C a ) Sigma/1 Control Version a Main drive Main drive/diaphragm Pump version: 12017* *For PVDF versions, max. 145 psig 12035* Note: Refer to technical data for capacities and stroke rates PVT SST Liquid end materials: PVDF with PTFE gasket 316 Stainless steel with PTFE gasket product overview solenoid-driven metering pumps Diaphragm type: 0 Standard diaphragm, PTFE 1 With double diaphragm and failure monitor (NC contact opens on fault) 2 With double diaphragm and failure monitor (alarm & continues to operate) Liquid end version: 0 Without valve springs 1 With 2 valve springs (Hastelloy C4, 1.45 psig) Connectors: 7 PVDF clamping nut & insert 8 SS clamping nut & insert Labeling: 0 Standard with logo motor-driven metering pumps U Voltage supply: 1 ph, V + 10%, 50/60 Hz A D U Cable and plug with 6 ft (2 m) power cord, single phase: European plug, 230 V N. American plug, 115 V N. American plug, 230 V Relay: 0 Without relay 1 Fault annunciating relay, drops out 3 Fault annunciating relay, pulls in 4 Option 1 + pacing relay 5 Option 3 + pacing relay C 4-20 ma output, drops out D 4-20 ma output, pulls in E 4-20 ma output, pacing relay Control variants: 0 Manual + External with pulse control (multiplier/divider) 1 Manual + External with pulse control & analog control 4 Option 0 + timer 5 Option 1 + timer P Option 1 + Profibus (Relay must be 0) Access code: 0 No access code 1 Access code Flow monitor: 0 Input for metering monitor signal (pulse) 1 Input for maintained flow switch signal C Stroke length adjustment: Manual + Calibration analytical sensors pump spare parts & accessories pump engineering specifications analytical instrumentation S1Ca H PVT U D C 78 4/21/ Sigma/ 1

21 ProMinent S i g m a / 1 Motor Diaphragm Metering Pumps D i m e n s i o n a l D r a w i n g : ( S 1 C a ) C 6.3 (160) A B F solenoid-driven metering pumps 14.9 (378) 4.7 (120) 5.4 (136) 7.7 (196) D/D (6.5) 1.1 (28) 4.7 (120 ) 7.8 (197) E/E1 max. 1.4 (36) Dimensions in inches (mm) motor-driven metering pumps Suction/ Discharge Valve Thread Type Sigma/1 A B C* D D1** E E1** F 12017, 12035, 10050, 10022, 10044, /2 MNPT PVT (279) (238) (90) (110) (275) (295) (96) SST /8 FNPT (248) (181) (89) (109) (275) (295) (96) 07042, 04084, PVT /4 MNPT (289) (254) (95) (115) (285) (305) (122) /2 FNPT SST (260) (206) (94) (114) (285) (305) (122) * Piping adapters provided according to technical data. ** Dimensions with diaphragm failure detector. analytical sensors analytical instrumentation pump spare parts & accessories pump engineering specifications product overview 80 4/21/ Sigma/ 1

22 Operating Instructions ProMinent Sigma/ 1 S1Ba (Basic Type) S1Ca (Control Type) ProMinent S1Ca S1Ca with left-hand liquid end S1Ba 01 S1Ca 01 Please enter the identity code of the device here. Two sets of operating instructions are necessary to ensure the ProMinent Sigma/ 1 S1Ba or S1Ca metering pumps are operated safely and reliably for their intended purpose: This product specific Sigma/ 1 operating instructions manual and the General operating instructions ProMinent motor-driven metering pumps and hydraulic accessories are only valid if read together! Please completely read through these operating instructions first! Do not discard! The warranty shall be invalidated by damage caused by operating errors! Part No ProMinent Dosiertechnik GmbH Heidelberg Germany BA SI /05 GB

23 Control elements and key functions Control elements: overview Operating light (green) 2 Warning light (yellow) 3 Error warning light (red) 4 Stroke length adjuster 5 LCD display 6 UP key 7 DOWN key 8 P key 9 STOP/START key 10 i key 11 Relay output (optional) 12 Metering monitor socket 13 Float switch socket 14 External control socket 15 Diaphragm rupture indicator socket 16 Mains switch Key functions In continuous display mode (operating) In settings mode (settings) STOP/START key STOP START Press briefly Stop pump, Stop pump, start pump start pump P key P Press briefly Start batch (in batch operating mode only), Confirm entry- jump to next menu Cancel error option or continuous display Press for 2 s Change to settings mode --- Press for 3 s --- Jump to continuous display Press for 10 s Software version displayed Press for 15 s Load factory settings (calibration) --- i key i Press x1 Toggle between continuous displays Toggle between change individual digits and change a figure" Press x2 --- For change individual digits : jumps to first digit Arrow keys UP and DOWN Press separately Change directly alterable values Select other settings, (until Set appears) change individual digit or figure Press simultaneously Prime (in Stroke rate permanent display)- ---

24 p. 50 First select the operating mode then enter the setting in the SET menu! Exceptions: Timer and PROFIBUS. p. 42 p. 48 p. 42 next page

25 Set previous page p. 44 p. 46 p. 47 Calib Set Set P Set Set p. 31 Set Calib Set Set p. 48 p. 48 p. 48

26 Operating mode Contact with memory and transfer factor 5 Operating mode Batch with memory and transfer factor 5

27 Imprint Dulcodes UV-Desinfektionsanlage Imprint Operating Instructions for ProMinent Sigma/ 1 S1Ba/S1Ca ProMinent Dosiertechnik GmbH, 2002 ProMinent Dosiertechnik GmbH Im Schuhmachergewann Heidelberg Germany info@prominent.com Subject to technical modifications. Page 6 ProMinent

28 Dulcodes UV-Desinfektionsanlage Table of contents Page Device Identification/Identcode 9 1 Notes on safety of ProMinent metering pumps Summary of additional safety instructions for the EX version of the pump (in accordance with ATEX) General notes Notes on installation, start-up and operation Notes on maintenance and repair 14 2 Product description S1Ba/S1Ca Identification of pump type Design/Functional description Functional description, drive Stroke movement Metering capacity diagram Functional description, delivery unit Integrated overflow valve with bleeder function Diaphragm rupture sensor 22 3 Technical data Technical data Sigma/ Capacity data Dimensions Sigma/ 1 Standart version Dimension sheet Sigma/ 1 with right-hand liquid end Dimension sheet Sigma/ 1 with left-hand liquid end Motor data Stroke actuator drive mechanism Stroke adjuster drive mechanism Electrical data, stroke sensor S1Ba Electrical data, pacing relay Sigma Sound intensity level 31 4 Start-up/Maintenance Start-up Maintenance Replacement of wearing parts 32 5 Features of the S1Ca metering pumps Function description, motors Function description, controller Sockets, symbols and wiring diagram Retrofitting relays (not by PROFIBUS version) 42 ProMinent Page 7

29 Table of contents Dulcodes UV-Desinfektionsanlage 6 Control elements 43 7 Settings Check adjustable values Change to settings mode Select operating mode (MODE menu) Settings for operating mode (SET menu) Exceptions: Timer and PROFIBUS Settings for manual operating mode Settings for analogue operating mode (ANALG menu) Settings for contact operating mode (CONTCT menu) Settings for batch operating mode (BATCH menu) Settings for programmable functions (SET menu) Settings for calibration function (CALIB menu) Settings for auxiliary frequency function (AUX menu) Settings for the flow function (FLOW menu) Setting code (CODE menu) Cancel total stroke number or total litres (CLEAR window) 52 8 Operating Manual operation Remote control 54 9 Troubleshooting Decommissioning and disposal Spare parts and accessories 57 Annex 58 Motor data sheet 58 EC Declaration of Conformity 59 Exploded diagrams of liquid ends 60 Stroke actuator wiring diagram 66 Wiring diagram for stroke length adjuster 66 Page 8 ProMinent

30 Dulcodes UV-Desinfektionsanlage Identcode ordering system Identcode ordering system Please enter the identcode on the device label into the grey box below. S1Ba Sigma Basic Type (S1Ba) H Main drive, diaphragm Pump type: (figures 1+2 = back pressure [bar], figures 3-5 = feed rate [l/h]) bar 17 l/h bar 35 l/h bar 50 l/h bar 22 l/h bar 44 l/h bar 65 l/h bar 42 l/h bar 84 l/h bar 120 l/h Liquid end materials: PV PVDF SS Stainless steel Seal material: T PTFE seal Diaphragm: 0 Standard diaphragm, PTFE version 1 Double diaphragm with diaphragm rupture indicator (retro fit possible) Liquid end version: 0 No spring 1 With 2 valve springs, Hastelloy C, 0.1 bar 4 With pressure relief valve, FPM seal, no valve spring 5 With pressure relief valve, FPM seal, and valve spring Hydraulic connection: 0 Standard threaded connector (according to technical data) 1 Union nut and PVC insert 2 Union nut and PP insert 3 Union nut and PVDF insert 4 Union nut and stainless steel insert 7 Union nut and PVDF hose nozzle 8 Union nut and stainless steel hose nozzle Version: 0 With ProMinent logo (standard) 1 Without ProMinent logo Electrical power supply: S 3 ph, 230 V/400 V 50/60 Hz, 0.09 kw M 1 ph, AC, 230 V/50 Hz, 0.12 kw N 1 ph, AC 115 V 60 Hz, 0.09 kw L 3 ph, 230 V/400 V, 50 Hz, (EExe, EExde) P 3 ph, 265 V/460 V, 60 Hz, (EExe, EExde) R 3 ph, variable speed motor, 230/400 V, 0.09 kw V Variable speed motor with integrated speed control 1 ph, 230 V, 50/60 Hz Z 1 ph, variable speed control set 1 ph, 230/400 V, 50/60 Hz 2 No motor, C 42 flange (NEMA) 3 No motor, B5 Gr. 56 (DN) Motor design: 0 IP 55 (standard) 1 Exe version (II 2G EEx e II T3) 2 Exde version (II 2G EEx de IIC T4) A ATEX design power end Stroke sensor: 0 No stroke sensor (standard) 1 with stroke sensor (Hall sensor, no connection cable) 2 Pacing relay (reed relay) 3 Stroke sensor (Namur) intrinsically safe Stroke length adjustment: 0 Manual (standard) 1 With stroke positioning motor, 230 V/50/60 Hz 2 With stroke positioning motor, 115 V/60 Hz 3 With stroke control motor, ma 230 V/50/60 Hz 4 With stroke control motor ma 230 V/50/60 Hz 5 With stroke control motor ma 115 V/60 Hz 6 With stroke control motor ma 115 V/60 Hz S1Ba 01 FPM = Fluorine Rubber ProMinent ProMinent Page 9

31 Identcode ordering system Dulcodes UV-Desinfektionsanlage Identcode ordering system Please enter the identcode on the device label into the grey box below. S1Ca Sigma Control Type (S1Ca) H Power end, diaphragm Pump typ: (figures 1+2 =back pressure [bar ],figures 3-5 =feed rate [l/h ]) bar 20 l/h Notice: bar 42 l/h S1Ca pump types: 60 Hz performance bar 50 l/h data applies (as 60 Hz operation) bar 26 l/h but max. 200 strokes/min bar 53 l/h bar 65 l/h bar 50 l/h bar 101 l/h bar 120 l/h Liquid end materials: PV PVDF SS Stainless steel Seal material: T PTFE seal Displacement element: 0 Standard diaphragm 1 Double diaphragm with rupture indicator incorporating Pump stopping function 2 Double diaphragm with rupture indicator incorporating Pump alarm function Liquid end version: 0 No springs 1 With 2 valve springs, Hastelloy C, 0.1 bar 4 With relief valve, FPM seal,no valve spring 5 With relief valve, FPM seal,with valve spring Hydraulic connection: 0 Standard threaded connector (according to technical data) 1 Union nut and PVC insert 2 Union nut and PP insert 3 Union nut and PVDF insert 4 Union nut and stainless steel insert 7 Union nut and PVDF hose nozzle 8 Union nut and stainless steel hose nozzle Version: 0 With ProMinent logo 1 Without ProMinent logo Electrical power supply: U 1 ph, 230 V/400 V, ±10 %, 50/60 Hz Cable and plug: A 2 m European B 2 m Swiss C 2 m Australian D 2 m USA Relays: 0 No relay 1 With fault indicating relay (N/C) 3 With fault indicating relay (N/O) 4 As 1 with pacing relay 5 As 3 with pacing relay F power relay N/C G power relay N/O Control variant: 0 Manual + external with pulse control 1 Manual + external + pulse control + analogue 4 as 0 + process-timer 5 as 1 + process-timer P PROFIBUS Access code: 0 No access code 1 With access code Metering monitor: 0 Input with pulse evaluation 1 Input with permanent contact evaluation Stroke length adjustment: 0 Manual C Manual + calibration S1Ca 01 FPM = Fluorine Rubber Page 10 ProMinent

32 Dulcodes UV-Desinfektionsanlage Notes on safety of ProMinent metering pumps 1 Notes on safety of ProMinent metering pumps General user instructions Please read through the following user instructions carefully! They will help you get the best use out of the operating instruction manual. The following are highlighted in the text: Enumerations Instructions Operating guidelines: NOTE Notices are intended to make your work easier. and safety guidelines: WARNING Describes a potentially dangerous situation. If not avoided. could cause fatal or serous injury. CAUTION Describes a potentially dangerous situation. If not avoided. could cause slight or minor injury or damage to property. IMPORTANT Describes a potentially damaging situation. If not avoided. could cause damage to property. Please also note the guidelines in General Operating Instruction Manual for ProMinent Motor- Driven Metering Pumps and Hydraulic Accessories! EX-pump only: The nameplates affixed to the title page are identical to those on the pump supplied to enable clear identification on the correct operating instruction manual for the pump. Please give the order number and the serial number, which you will find on the nameplates of the pump itself, in the event of any query or spare part order. This facilitates identification of the pump. 1.1 Summary of additional safety instructions for the EX version of the pump (in accordance with ATEX) WARNING In explosion-threatened workplaces in zone 1, device category II 2G of explosion group II C the pump may not be operated without the corresponding rating plate (and the corresponding EC conformity declaration) for pumps for explosion-threatened workplaces in accordance with guideline 94/9/EC of the European guidelines. From July 1st, 2003 on, only pumps with the corresponding marking according to EC-Exdirective 94/9 may be used in industrial premises with potentially explosive atmospheres. The explosion group, category and type of protection shown on the marking must correspond to or exceed the conditions prevailing in the intended area of application. All other uses or modifications are prohibited! ProMinent Page 11

33 Notes on safety of ProMinent metering pumps Dulcodes UV-Desinfektionsanlage Pumps may never be operated in explosion-threatened workplaces without a corresponding rating plate (and the corresponding EC conformity declaration) for pumps for explosion-threatened workplaces. Installations in potentially explosive atmospheres must be inspected by a accredited qualified person. This applies in particular also for intrinsically safe electrical circuits. Drive motors must be secured by an appropriate motor protection switch. A motor protection approved for this application must be used for Ex e -motors. (Protection against heating due to overload) Observe all relevant standards e.g. DIN EN 60079, DIN EN 50020, DIN VDE 0165 and/or DIN VDE 0118 Installing electrical equipment in explosion-threatened areas! When installing the metering pump, observe the directives for the installation of devices in explosion-threatened areas, e.g. for Europe the European operator s guideline 99/92/ EC (ATEX137)*, (in Germany implemented via the new operating safety ordinance (Official Federal Gazette for 2002, Part 1, No. 70, issued in Bonn ))! * previously ElexV Observe documents supplied with individual electric components! On principle, metering pumps in potentially explosive atmospheres must be equipped with a safety overflow valve at the outlet side of the pump (serves as protection against overheating due to overload and against sparks produced by shock due to overload which has led to the breakage drive parts.) When using with flammable media: - Diaphragm pumps with mechanically actuated diaphragm: no additional measures necessary, however, version with diaphragm rupture indicator, version Ex i *, must be used on principle. - For all metering pumps for metering inflammable media applies: starting up and emptying only supervised by a competent person. - Inflammable media may only be lifted with stainless steel liquid ends. - For exceptional cases, where this is not possible, also PTFE with carbon may be used, our versions TT_ are made of conductive plastics. In this case, special attention must be paid by the user due to the lower mechanical stability. If using the metering pump for Europe e.g. the European operator s guideline 99/92/EC* (ATEX 137**), (in Germany implemented via the new operating safety ordinance (Official Federal Gazette for 2002, Part 1, No. 70, issued in Bonn ) and the German dangerous chemicals ordinance))! * previously Ex Vo, Vb F ** previously ATEX118A Observe also all relevant standards e.g. DIN EN /14 and DIN EN for installations in explosion-threatened areas! Note all national directives which apply to the installation! Wear parts (diaphragms, bearings etc.) of metering pumps used in potentially explosive atmospheres must be replaced after having completed 90% of their nominal product life. The proper general function, in particular of the drive, must be safeguarded by regular inspections (leakages, noises, temperatures, possible discoloration due to excess temperatures...). Use original spare parts should exchange become necessary! Check that the pressure relief valve downstream from the pump is functioning correctly! The pressure relief valve must prevent the gearbox from being overloaded and overheating in explosion-threatened workplaces! When cleaning plastic parts, attention must be paid to not generating any electrostatic charge by rubbing excessively. - see danger sign. These measures are the minimum protection measures specified bei ProMinent. Should the user know about any further risks, it is his duty to eliminate them by taking corresponding measures. Page 12 ProMinent

34 Dulcodes UV-Desinfektionsanlage Notes on safety of ProMinent metering pumps Safety devices The following safety notice must be affixed to the pump (by PP, PC and PV liquid ends, acrylic glass cover,...) ATTENTION Because of danger of electrostatical ignition use damp cloth only for wiping plastic parts! EC conformity declaration / certificates The EC conformity declaration for pumps for explosion-threatened workplaces is supplied with the pump (the copy of the EC conformity declaration for the pump itself does not apply to pumps designed for explosion-threatened workplaces). The EC conformity declarations, the EC series prototype test reports and the operating manuals for the individual components are also supplied with the pump. 1.2 General notes WARNING The equipment/devices may only be used for their intended purpose. ProMinent metering pumps must not be assembled with parts which are not tested and recommended by ProMinent otherwise this can lead to injury to persons and damage to property for which no liability will be accepted! Pumps must be accessible at all times to facilitate operation and maintenance. Access points must not be obstructed or blocked! Before carrying out any maintenance and repair work always drain off and flush out the liquid end first if hazardous or unknown metered media are used! When metering hazardous or unknown liquids, always wear safety clothing (safety goggles, gloves,...) when working on the liquid end! You must observe the guidelines in this operating instructions manual and the General operating instructions manual for ProMinent motor-driven metering pumps and hydraulic accessoires on assembly, installation and maintenance! 1.3 Notes on installation, start-up and operation WARNING The metering pump can contain water residue in the liquid end as the result of testing at the factory! If handling media which must not come in contact with water, all traces of water must be removed from the liquid end before start-up! For this purpose, turn the pump through 180 and drain off the liquid end then flush with a suitable medium from above via the intake connection! Do not connect mains voltage to the control cable! When operating the metering pump against a closed shut-off element on the pressure side or in the event of pressure peaks during the metering stroke, the system pressure can reach a multiple of the maximum permissible operating pressure that can consequently cause the pressure line to burst! To avoid this situation, an overflow is recommended for the purpose of limiting the maximum permissible operating pressure of the pump or system. Do not connect a metal bypass line to the overflow valve on the PVT delivery unit! This could cause cracks in the delivery unit! ProMinent Page 13

35 Notes on safety of ProMinent metering pumps Dulcodes UV-Desinfektionsanlage The bearing cover (1) must be fitted when in operation. The equipment will not otherwise comply with IP 55 and the bearing will not be adequately secured! The design cover (2) must be fitted when in operation. Equipment will not otherwise comply with IP 55. IMPORTANT Set stroke length only with pump in operation! 1 Fig. 1 2 NOTE The pump must be secured in such a way that no vibrations can occur! The valves of the liquid end must always be positioned vertically in order to ensure trouble-free operation! The intake and delivery lines must always be arranged such as to ensure connection at the liquid end free of mechanical stress! The lines must be secured so that no vibrations can occur! Only use the clamping rings and hose sockets intended for the relevant hose diameter as well as original hoses with the specified hose dimensions and wall thickness otherwise the stability and durability of the connection will not be guaranteed! Avoid reducing hose sizes! Observe the permissible pressure of the hoses! A vent with return to the supply tank is advisable when metering extremely aggressive or hazardous media! In addition, a shut-off valve should be provided on the delivery or intake side! 1.4 Notes on maintenance and repair WARNING Only specially trained and authorized persons are permitted to carry out maintenance on metering pumps and their peripherals! If hazardous or unknown metering media are used, always flush out the liquid end first before carrying out any maintenance and repair work! When metering hazardous or unknown liquids, always wear safety clothing (safety goggles, gloves) when working on the liquid end! Always depressurize the delivery line first before carrying out any work on the pump! Always discharge and flush liquid end! Observe safety data sheets for metered liquid! DANGER Disconnect power plug or power supply line before opening the plug! Isolate relay option if applicable! Check to ensure power is disconnected! Secure pump while carrying out repairs to ensure it cannot be switched on unintentionally! Pumps for metering radioactive media must not be shipped through standard channels! NOTE The metering pump must be in a cleaned condition with the liquid end flushed if returned for repair! Page 14 ProMinent

36 Dulcodes UV-Desinfektionsanlage Product description S1Ba/S1Ca 2 Product description S1Ba/S1Ca WARNING Use for intended purpose The pump is designed as a liquid medium metering pump; it serves the purpose of metering liquid medium within the specified line system! In explosion-threatened workplaces in zone 1, device category II 2G of explosion group II C the pump may not be operated without the corresponding rating plate (and the corresponding EC conformity declaration) for pumps for explosion-threatened workplaces in accordance with guideline 94/9/EC of the European guidelines. From July 1st, 2003 on, only pumps with the corresponding marking according to EC-Exdirective 94/9 may be used in industrial premises with potentially explosive atmospheres. The explosion group, category and type of protection shown on the marking must correspond to or exceed the conditions prevailing in the intended area of application. Operate the pump only within the conditions described in the technical data! General restrictions with regard to viscosity limits, chemical resistance and density must be observed (refer to ProMinent chemical resistance list (catalogue or homepage))! All other applications or conversion are prohibited! The pump is not designed to meter gaseous media as well as solids. Non-EX-pump: The pump is not suitable for metering combustible liquids! Pumps may never be operated in explosion-threatened workplaces without a corresponding rating plate (and the corresponding EC conformity declaration) for pumps for explosion-threatened workplaces. Only specifically trained and authorized personnel are permitted to operate the pump! 2.1 Identification of pump type Fig. 2 The identity code and serial number are given in addition to the standard technical specifications. These two numbers must always be quoted when making any enquiries as they enable clear identification of the type of metering pump. 2.2 Design/Functional description Functional description, drive The ProMinent Sigma/ 1 diaphragm-type metering pump is an oscillatory displacement pump with the stroke length adjustable in steps of 1%. It is driven by electric motor (1). The rotary drive of the electric motor is stepped down by worm gear and transmitted via the eccentric roller (3) to the push rod (4) connected to fork (8) and converted into oscillatory movement. Return spring (5) presses the fork with push rod positively against the eccentric roller thus producing the return stroke. The stroke is adjusted by means of stroke adjustment knob (6) and spindle (7) by limiting the return stroke. Stroke movement is transmitted directly to the displacement diaphragm. Interacting with the valves, this diaphragm produces the overpressure and vacuum in the liquid end necessary for delivery. Flow is pulsating. In the basic type, the electric motor is normally a 3-ph extended-range AC motor (refer to Section 3 for other options). ProMinent Page 15

37 Product description S1Ba/S1Ca Dulcodes UV-Desinfektionsanlage Fig. 3 61_01-101_00_ Stroke movement a) Stroke progression at max. stroke rate and stroke length b) At reduced stroke length Stroke speed + Delivery stroke Intake stroke Angle reduced stroke length Fig. 4 Set stroke length dependent on the required delivery capacity. 75 % 30 % NOTE A large stroke length and low metering frequency should be selected for very viscous media! A shorter stroke length and high frequency should be selected to achieve good mixing properties! Fig. 5 Page 16 ProMinent

38 Dulcodes UV-Desinfektionsanlage Product description S1Ba/S1Ca Metering capacity diagram Metering capacity diagram S1Ba (50 Hz) S1Ba10050 S1Ba12035 S1Ba S1Ba10050 S1Ba12035 S1Ba Metering capacity diagram S1Ba (50 Hz) S1Ba07065 S1Ba10044 S1Ba Q (l/h) Q (l/h) Q (l/h) Q (l/h) Stroke length in (%) Metering capacity diagram S1Ba (50 Hz) pressure in (bar) Stroke length in (%) Metering capacity diagram S1Ba (50 Hz) S1Ba07065 S1Ba10044 S1Ba pressure in (bar) ProMinent Page 17

39 Product description S1Ba/S1Ca Dulcodes UV-Desinfektionsanlage Metering capacity diagram S1Ba (50 Hz) S1Ba04120 S1Ba04084 S1Ba Stroke length in (%) Metering capacity diagram S1Ba (50 Hz) S1Ba04120 S1Ba04084 S1Ba pressure in (bar) Q (l/h) Q (l/h) NOTE The metering output of S1Ba at 60 Hz is approximately 1.2 times the metering output of S1Ba at 50 Hz. For pump types S1Ca, the output data at 60 Hz apply (for S1Ca, however, only 200 strokes/min. are possible). Page 18 ProMinent

40 Dulcodes UV-Desinfektionsanlage Product description S1Ba/S1Ca Functional description, delivery unit The heart of the delivery unit is the DEVELOPAN metering diaphragm (2). It hermetically seals the delivery chamber of the liquid end (4) and produces a displacement in the liquid end. The end disc (5) made of chemically resistant plastic together with safety diaphragm (13) separates the drive housing from the delivery unit and protects the drive from corrosion in the event of the diaphragm failing. Delivery is based on the interaction between intake valve (1) and head valve (3) of the same design together with the diaphragm movement. The valve balls can be supported with springs for metering viscous media. The connection dimensions of valves and liquid ends of the same size but with different materials are identical. These parts can be interchanged as required. Materials and dimensions are specified in Section 3, Technical data. Fig ProMinent Page 19

41 Product description S1Ba/S1Ca Dulcodes UV-Desinfektionsanlage Integrated overflow valve with bleeder function Task: The task of the overflow valve is to protect the motor and gear unit against impermissible overpressure caused by the metering pump. This function is produced by a spring-loaded ball. A pressure relief mechanism for the bleeder function is provided. Design and functional description (refer to Fig. No. 7 and 8) Initially, the overflow valve illustrated under item 102 operates as a simple directly controlled safety valve. As soon as the pressure set with spring item 132 is exceeded, the effective pressure raises ball item 130. The liquid then flows off into the tank via hose connection item * Overflow valve Sigma/ 1 liquid end, 12 bar PVT Identcode Type: Overflow valve Sigma/ 1 liquid end, 10 bar PVT Identcode Type: 10044, Overflow valve Sigma/ 1 liquid end, 7 bar PVT Identcode Type: 07042, Overflow valve Sigma/ 1 liquid end, 4 bar PVT Identcode Type: Fig Page 20 ProMinent

42 Dulcodes UV-Desinfektionsanlage Product description S1Ba/S1Ca * Overflow valve Sigma/ 1 liquid end, 12 bar SST Identcode Type: Overflow valve Sigma/ 1 liquid end, 10 bar SST Identcode Type: 10044, Overflow valve Sigma/ 1 liquid end, 7 bar SST Identcode Type: 07042, Overflow valve Sigma/ 1 liquid end, 4 bar SST Identcode Type: Fig IMPORTANT Knob item 139 must be turned in a clockwise direction as far as it will go towards close. The bypass line must always be closed and must be routed back into the supply tank. Connection via hose connection item 128. Minimal overflow can occur in the bypass line when the valve operates close to the overpressure function. The bleeder function is achieved by turning knob item 139 in counterclockwise direction as far as it will go towards open : Priming aid for starting up pump against pressure. The force of spring item 132 relieves ball item 130 which is controlled by the lower spring force of bleeder spring item 133. IMPORTANT Once the pump has primed, turn knob item 139 in a clockwise direction as far as it will go towards close! The pump can now be operational. ProMinent Page 21

43 Product description S1Ba/S1Ca Dulcodes UV-Desinfektionsanlage Technical data Corresponding to the type of pump, overflow valves are available for pressure stages p nom 4, 7, 10 and 12 bar with ( ) xp nom opening pressure. Material in contact with metered medium Material Liquid end Suction/ Seals Balls Springs Integrated version discharge overload connector valve PVT PVDF PVDF PTFE Ceramic / glass Stainless steel PDFE/FPM SST Stainless steel Stainless steel PTFE Stainless steel Stainless steel Stainless steel/ / FPM FPM = Fluorine Rubber Use for intended purpose/use for unintended purpose Use for intended purpose Protect the dosing pump against unacceptable high overpressure produced by the dosing pump. Use the overflow valve only in connection with liquids with a viscosity of up to max. 200 mpa s. IMPORTANT The ceramic ball and ball seat of the overflow valve are wearing parts. Slight leakage can occur at the safety valve after a prolonged period of operation. The ball and ball seat should be replaced if leaks occur. The bypass line must always be connected and must be routed back into the supply tank. Use for unintended purpose To protect the system from impermissible overpressure. The pump must not be operated without the bypass line connected. The bypass line must not be connected in the intake line (the bleeder function will no longer be guaranteed). The bypass line must be routed back into the supply tank. WARNING When carrying out maintenance work on the overcurrent valve, pay attention to the tensioning state of the pressure spring item132! Wear safety goggles! Diaphragm rupture sensor Function: Monitors the seals in the working diaphragm. This liquid end can continue to function for a short period in emergency mode, i.e. full operating pressure, no leakage, even after diaphragm rupture. Design and function description (see Fig. 9) Liquid ends with diaphragm rupture sensors comprise a standard liquid end (item 100) a working diaphragm (item 200) and an auxiliary diaphragm (item 148) The auxiliary diaphragm is positioned between the back plate (item 201) and the interim plate (item 147) and forms a sealed compartment together with the working membrane (item 200). The leak tightness of the working diaphragm, Item 200, is monitored with a diaphragm failure detector, Item 104, that triggers a contact signal in the event of diaphragm failure so that the pump is stopped in the S1Ca and the diaphragm failure is indicated on a LCD. The liquid end can continue to operate in emergency mode, i.e. full operating pressure, no leakage, even after diaphragm rupture, until the diaphragm has been replaced. We offer two versions of the S3Ca with diaphragm rupture sensor: After a working diaphragm rupture, the pump stops and an error message/diaphragm sensor signal is given. Page 22 ProMinent

44 Dulcodes UV-Desinfektionsanlage Product description S1Ba/S1Ca After a working diaphragm rupture, the pump will continue to run. An error message/ electrical signal is given. A function plug is supplied which allows the pump to continue operating after a fault has occurred (diaphragm rupture, failure of the diaphragm rupture sensor). WARNING EX-pump only: Installations in potentially explosive atmospheres must be inspected by a accredited qualified person. This applies in particular also for intrinsically safe electrical circuits. EX-pump only: observe documents supplied with the sensor! IMPORTANT In the case of the S1Ba, the customer should install a diaphragm rupture signal monitor and/or ensure that the pump will stop after a diaphragm rupture. In the event of diaphragm failure, a contact signal is triggered as from 2 bar system backpressure. Exact pump delivery can no longer be guaranteed after failure of the working diaphragm. The auxiliary diaphragm, Item 148, is a wearing part and must be replaced after failure of the working diaphragm. The diaphragm rupture sensor lens, Item 156, should be replaced after every diaphragm rupture FM 050 Identcode Type: 10022, 10044, 10050, 12017, FM 065 Identcode Type: 07042, FM 120 Identcode Type: 04084, Fig ProMinent Page 23

45 Product description S1Ba/S1Ca Dulcodes UV-Desinfektionsanlage Material in contact with metered medium Liquid end: Parts of diaphragm failure monitor in contact with medium Lens, seals Intermediate disc Item 147, Item 148, 156, 159 intermediate bush Item 150 PVDF PTFE PVDF Stainless steel PTFE PVDF Blue - Brown + Electrical data for the diaphragm rupture sensor a) switch contact 30 V DC/1 A or 125 V AC/0.6 A or 250 V AC/0.3 A The diaphragm sensor is a N/C relay. IMPORTANT Before commencing operation, install the provided diaphragm breakage sensor together with the gasket (Item159) and make the electrical connections. NOTE For safety reasons it is advisable to connect a safe low voltage (e.g. EN (SELV)). The cable priority is arbitrary. b) Stroke sensor, intrinsically safe 5-25 V DC, Namur type and/or DIN 19234, zero volt design. Rated voltage: 8 V DC (R i ~ 1 kω) Power consumption: Active surface, uncovered > 3 ma Active surface, covered < 2 ma Rated switching distance: 1.5 mm The monitor/feeder must be capable of evaluating current changes in order to indicate diaphragm rupture! WARNING EX-pump only: Installations in potentially explosive atmospheres must be inspected by a accredited qualified person. This applies in particular also for intrinsically safe electrical circuits. EX-pump only: observe documents supplied with the sensor! IMPORTANT Before commencing operation, install the provided diaphragm breakage sensor together with the gasket (Item159) and make the electrical connections. Non-EX-pump: For safety reasons it is advisable to connect a safe low voltage (e.g. EN (SELV)). Page 24 ProMinent

46 Dulcodes UV-Desinfektionsanlage Technical data 3 Technical data 3.1 Technical data Sigma/ Capacity data Technical data S1Ba at 50 Hz operation Feed rate at Max. Suction Admissible Connection Shipping maximum stroke lift priming suction / weight back pressure rate pressure discharge suction side side Pump type bar l/h ml/ strokes/ m WC bar R" - DN kg Sigma/ stroke min PVT /4" SST /4" PVT /4" SST /4" PVT /4" SST /4" PVT /4" SST /4" PVT /4" SST /4" PVT /4" SST /4" PVT " SST " PVT " SST "/ PVT " SST " All performance data applies to water at 20 C. The suction lift applies when the suction line and liquid end are full and correctly installed. ProMinent Page 25

47 Technical data Dulcodes UV-Desinfektionsanlage Technical data S1Ba at 60 Hz operation and S1Ca Feed rate at Max. Suction Admissible Connection Shipping maximum stroke lift priming suction / weight back pressure rate pressure discharge suction side side Pump type bar psi l/h gph strokes/ m WC bar R"-DN kg Sigma min PVT /4" SST /4" PVT /4" SST /4" PVT (50*) (200*) /4" SST (50*) (200*) /4" PVT /4" SST /4" PVT /4" SST /4" PVT (65*) (200*) /4" SST (65*) (200*) /4" PVT " SST " PVT " SST " PVT (120*) (200*) 3 1 1" SST (120*) (200*) 3 1 1" * Values for S1Ca All performance data applies to water at 20 C. The suction lift applies when the suction line and liquid end are full and correctly installed. Materials in contact with chemicals Material Liquid end Suction/ Seals Balls Springs Integrated version discharge overload valve connector PVT PVDF PVDF PTFE Ceramic / glass Stainless steel PDFE/Viton SST Stainless steel Stainless steel PTFE Stainless steel Stainless steel Stainless steel/ / PTFE Viton Temperature specifications Permissible storage temperature: 10 to +50 C Permissible ambient temperature: 10 to +40 C Temperature compatibility (medium temperature) of materials Material: Long-term at max. Short-term, max. 15 min. backpressure: at max. 2 bar PVT 65 C 100 C SST 90 C 120 C The specified temperatures (see above) can be exceeded temporarily, e.g. for sterilisation or flushing with hot water. Accuracy Under constant conditions and in minimum stroke length of 30 % corresponding to following notes, the reproducibility of the metered quantity is better than ±2 %. All specifications refer to metered quantities with water at 20 C and correct installation of the metering pump. Page 26 ProMinent

48 Dulcodes UV-Desinfektionsanlage Technical data Dimensions Sigma/ 1 Standart version C Connection variations B ø 135 ø G PVDF 160 A 378 PP/PVC/PTFE F D/D1 ø E/E H/H1/H2 SS Fig _01-101_00_45-73 Dimensions Sigma/ 1 in mm Typ Connector A B C D D1* E E1* F Ø G H# H1## H2### Sigma 12017, 12035, 10022, DN G 3/4 A , PVT Sigma 12017, 12035, 10022, 10044, DN G 3/4 A , PVT - ÜV-A Sigma 12017, 12035, 10022, 10044, DN G 3/4 A , SST Sigma 12017, 12035, 10022, 10044, DN G 3/4 A , SST - ÜV-A Sigma 07042, 04084, DN G 1 A PVT Sigma 07042, 04084, DN G 1 A PVT - ÜV-A Sigma 07042, 04084, DN G 1 A SST Sigma 07042, 04084, DN G 1 A SST - ÜV-A Dimensions with: * diaphragm rupture sensor, # cover, basic model ## Controller cover, ### Controller cover (pacing relay) ProMinent Page 27

49 Technical data Dulcodes UV-Desinfektionsanlage Dimension sheet Sigma/ 1 with right-hand liquid end* C Anschlussvarianten 160 A B G F E/E1 D/D H/H1/H2 Fig _01-101_00_45-73_2 * Custom version on request Dimensions Sigma/ 1 in mm Typ Connector A B C D D1** E E1** F Ø G H# H1## H2### Sigma 12017, 12035, 10022, DN G 3/4 A , PVT Sigma 12017, 12035, 10022, 10044, DN G 3/4 A , PVT - ÜV-A Sigma 12017, 12035, 10022, 10044, DN G 3/4 A , SST Sigma 12017, 12035, 10022, 10044, DN G 3/4 A , SST - ÜV-A Sigma 07042, 04084, DN G 1 A PVT Sigma 07042, 04084, DN G 1 A PVT - ÜV-A Sigma 07042, 04084, DN G 1 A SST Sigma 07042, 04084, DN G 1 A SST - ÜV-A Dimensions with: ** diaphragm rupture sensor, # cover, basic model ## Controller cover, ### Controller cover (pacing relay) Page 28 ProMinent

50 Dulcodes UV-Desinfektionsanlage Technical data Dimension sheet Sigma/ 1 with left-hand liquid end* C 160 A B 135 G 378 F D/D H/H1/H2 Table of variable dimensions, see Dimensions in mm * Custom version on request E/E1 266 Fig _01-101_00_45-73_ Motor data Electrical Data Motors: Identcode characteristic 3 ph IP V/400 V 50 Hz 0.09 kw 0.7/0.39 S 3 ph IP V/460 V 60 Hz 0.09 kw 0.68/0.38 S 1 ph AC 230 V 50 Hz 0.12 kw 1.2 M 1 ph AC 115 V 60 Hz 0.12 kw 2.4 N 3 ph EXe or EXde 230 V/400 V 50 Hz 0.12 kw 0.58 L 3 ph EXe 265 V/460 V 60 Hz 0.18 kw 0.64 P 3 ph EXde V 60 Hz 0.18 kw V 3 ph IP V/400 V 50/60 Hz 0.09 kw... R Version with external fan 1 PH 230 v; 50/60 Hz and PTC 1 ph IP V 50 Hz 0.09 kw... V Three phase motor with integrated speed changer For more details you can request the motor specification sheets. Custom motors and/or custom motor flanges are available on request. WARNING EX-pump only: Drive motors must be secured by an appropriate motor protection switch. A motor protection approved for this application must be used for Ex e -motors. (Protection against heating due to overload) EX-pump only: motors in EX-areas must be installed and checked by persons with recognised skills! EX-pump only: observe the operating manual supplied with the EX motor! ProMinent Page 29

51 Technical data Dulcodes UV-Desinfektionsanlage direction of rotation Fuse data IMPORTANT The motors are not fuse-protected. Fit a motor circuit breaker. When connecting the motor, make sure that it rotates in the correct direction Protection against accidental contact and moisture (IP) Motor: IP 55 DIN EN (in accordance with DIN VDE 0470 Part 1, corresponds to EN and IEC 529). Humidity max. humidity: 90% relative humidity, non condensing External fan Notes on the speed-controlled motor with separate fan and temperature monitoring may be found in the General Operating Instructions ProMinent Motor-Driven Metering Pumps and Hydraulic Accessories Stroke actuator drive mechanism 230 V ± 10 % 50/60 Hz 11.7 W 115 V ± 10 % 60 Hz 11.7 W Cf. Appendix for terminal connection diagram Stroke adjuster drive mechanism 230 V ± 10 % 50/60 Hz 6.5 W 115 V ± 10 % 60 Hz 6.5 W Cf. Appendix for terminal connection diagram Electrical data, stroke sensor S1Ba a) Reed contact (Identcode characteristic Stroke sensor : 1) Pin 1 (white) = 4.5 V to 24 V, max. 10 ma Pin 2 (brown) = OUT, open collector, 24 V, 20 ma Pin 3 (green) = GND Pulse width (low) 4 ms (depending on gearbox and power frequency) b) Stroke sensor, intrinsically safe (Identcode characteristic Stroke sensor : 3) WARNING EX-pump only: intrinsically safe installations must be installed and checked by persons with recognised skills! EX-pump only: observe documents supplied with the sensor! Blue - Brown V DC, Namur type and/or DIN 19234, zero volt design. Rated voltage: 8 V DC (R i ~ 1 kω) Power consumption: Active surface, uncovered > 3 ma Active surface, covered < 2 ma Rated switching distance: 1.5 mm The monitor/feeder must be capable of evaluating current changes in order to indicate diaphragm rupture! Page 30 ProMinent

52 Dulcodes UV-Desinfektionsanlage Technical data / Start-up/Maintenance Electrical data, pacing relay Sigma Relay input (power supply for the relay board) Input voltage Mains frequency Power consumption 200/230 V AC ( V) 50/60 Hz 10 ma (230 V/50 Hz) 100/115 V AC ( V) 50/60 Hz 15 ma (115 V/60 Hz) 24 V DC (20-28 V) - 10 ma at 24 V DC Relay output Voltage, max. Current, max. Hook up duration Standard 24 V DC 100 ma 100 ms adjustable The contacts are zero volt Sound intensity level The sound intensity level is < 70 db (A) at maximum stroke, maximum stroking rate, maximum back pressure (water) in accordance with DIN EN (noise measurement in fluid pumps) 4 Start-up/Maintenance IMPORTANT Observe the safety notes provided in Section Start-up All general guidelines in the accompanying General operating instructions ProMinent motordriven metering pumps and hydraulic accessories apply. WARNING EX-pump only: Diaphragm pumps with mechanically actuated diaphragm: no additional measures necessary, however, version with diaphragm rupture indicator, version Ex i *, must be used on principle. For all metering pumps for metering inflammable media applies: starting up and emptying only supervised by a competent person. Inflammable media may only be lifted with stainless steel liquid ends. - For exceptional cases, where this is not possible, also PTFE with carbon may be used, our versions TT_ are made of conductive plastics. In this case, special attention must be paid by the user due to the lower mechanical stability. 4.2 Maintenance WARNING EX-pump only: Wear parts (diaphragms, bearings etc.) of metering pumps used in potentially explosive atmospheres must be replaced after having completed 90% of their nominal product life. EX-pump only: check that the pressure relief valve downstream from the pump is functioning correctly! The pressure relief valve must prevent the gearbox from being overloaded and overheating in explosion-threatened workplaces! ProMinent Page 31

53 Start-up/Maintenance Dulcodes UV-Desinfektionsanlage The proper general function, in particular of the drive, must be safeguarded by regular inspections (leakages, noises, temperatures, possible discoloration due to excess temperatures...). Use original spare parts should exchange become necessary! EX-pump only: When cleaning plastic parts, attention must be paid to not generating any electrostatic charge by rubbing excessively. - see danger sign. EX-pump only: metering pumps and their peripheral equipment must be serviced by specially trained or authorised personnel! IMPORTANT After loosening the liquid end screws (e.g. to change the valves or diaphragm), the screws must be retightend clockwise to the specified tightening torque. What requires maintenance? Secure fit of liquid end screws. Secure fit of metering lines (intake and delivery sides). Secure fit of head valve and intake valve. Leakage hole at end disc for moisture (indicates possible diaphragm failure). Operate pump continuously for a short period of time in order to check whether it delivers correctly. Maintenance intervals General recommendation for maintenance intervals - every 3 months. Shorter intervals are recommended if operated under load conditions (e.g. continuous operation). The metering diaphragm is a wearing part whose service life is dependent on the following parameters: System backpressure. Operating temperature. Properties of medium to be metered. The service life of the diaphragm is restricted in the case of abrasive media. In such cases, it is recommended to check the diaphragm more frequently and to install a diaphragm failure monitor. 4.3 Replacement of wearing parts WARNING EX-pump only: metering pumps and their peripheral equipment must be serviced by specially trained or authorised personnel! Always use original spare parts. Replacing diaphragm (see exploded diagrams in appendix!) IMPORTANT Flush liquid end first in the case of hazardous media. For this purpose, force water or a suitable flushing agent through the intake connection of the liquid end with a wash bottle. Set stroke length to zero with the pump running. Switch off pump. Release the six screws holding the liquid end, detach liquid end together with screws. Release diaphragm from the push rod by jolting in counterclockwise direction and unscrew. Screw on new diaphragm until it is firmly seated on the push rod. Mount the dosing head with screws such that the suction connection lies at the bottom (observe the flow through direction / arrow marks on the valves). Switch on pump. Set stroke length to 100% and turn in screws then tighten clockwise to 4.5 ± 0.5 Nm. Check pump for leaks at max. pressure. Page 32 ProMinent

54 Dulcodes UV-Desinfektionsanlage Start-up/Maintenance NOTE The tightening torque of the liquid end screws should be rechecked after 24 hours of operation. The tightening torques of the liquid end screws should be checked every 3 months for the PVT material version. Fig. 14 S3Ba/S3Ca-014-GB GUIDELINE ON VALVE INSTALLATION In the case of suction problems during installation, place the valves on a firm surface and tap the PTFE ball seat disk lightly with a brass rod and a hammer weighing about 300 g. Let the valves remain in the wet state. approx. 300 g Brass rod 9 mm diam. x approx. 200 mm Fig. 15 S3Ba/S3Ca-019-GB NOTE If suction problems with the pump or leakage at the overcurrent valve are encountered, first clean the ball and the ball seat disc. For media containing particles larger than 0.3 mm it is absolutely essential to install a filter in the suction line. ProMinent Page 33

55 Features of the S1Ca metering pumps Dulcodes UV-Desinfektionsanlage 5 Features of the S1Ca metering pumps 5.1 Function description, motors The pump has an integrated electronic overload cut-out in all versions. This responds as soon as the maximum admissible power consumption is reached and stops the motor. If the motor stops due to a system overload the electronic controller detects the fault and transmits a message which is displayed on the display panel and at the pump. The fault signal can be cancelled by pressing the P key, altering the level for a brief period at the pause input (switch function) or by reconnecting the pump to the mains. IMPORTANT If the pump has been switched off by the thermal overload protection, check that it is not permanently overloaded. NOTE S1Ca-Pump types - in general 60 Hz performance data applies (because 60 Hz internal operation). The controller changes over to digital stroking mode at low stroke frequencies! This takes place at stroke frequencies below 1/3 of the maximum stroke frequency. This function is designed to ensure sufficient cooling of the motor and low stroke frequencies. Humidity max. humidity: 90% relative humidity, non condensing 5.2 Function description, controller Electrical Data S1Ca pump Type: V ± 10 %, 50/60 Hz at 100 V at 230 V Nominal output 130 W 130 W Nominal current A Peak current (in operation) 3 A 3 A Making peak current 8 A 16 A Fuse, internal* 3.15 AT (1.5kA) 3.15 AT (1.5kA) * Only genuine ProMinent fuses, item no , may be used! Page 34 ProMinent

56 Dulcodes UV-Desinfektionsanlage Features of the S1Ca metering pumps Operating modes Functions Operating modes are selected using the MODE menu (depending upon identity code, some operating modes may be absent). Analogue operating mode: (Identity code, control variant: analogue) The stroke rate is controlled via an analogue electrical signal via the external control terminal. Signal processing is pre-selected at the controller. Manual operating mode: The stroke rate is controlled manually via the controller. Contact operating mode: This operating mode offers the opportunity to make fine adjustments with small increase/ decrease factors. Dosing can be activated by a pulse via the external control terminal or by a semiconductor element. With the pulse control option it is possible to pre-set a feed quantity (batch) or number of strokes (factor 0.01 to 99.99) via the control unit. Batch operating function: This operating mode offers the option of working with larger transfer factors (up to 65535). Metering can be triggered by pressing the P key or a pulse from the external control terminal via a contact or semiconductor element. A batching quantity or number of strokes can be preselected via the control unit. PROFIBUS mode: (Identity code, control variant: PROFIBUS ) This operating mode provides the option of controlling the pump via the PROFIBUS (see Supplementary instructions for ProMinent gamma/ L and ProMinent Sigma versions with PROFIBUS ). The following functions can be selected using the SET menu: Calibrate function: The S1Ca can be operated in all operating modes including in calibrating mode. The corresponding continuous displays can show the actual feed quantity or the feed rate. Calibration is maintained within the stroke frequency range strokes/ min. Calibration is also maintained when a stroke frequency is altered up to ±10 % scale divisions. Auxiliary frequency function: It is possible to set a stroke rate in the SET menu, which may be activated via the external control terminal. This auxiliary frequency overrides all other pre-set stroke rate frequencies. Flow function: Stops the S1Ca when the flow is insufficient. In the SET menu, the number of failed strokes is entered after which the pump will be turned off. The following functions are available as standard: Float switch function: Information on the liquid level in the feed chemical container is transmitted to the S1Ca. This option requires the installation of a 2-stage float switch. This is connected to the float switch terminal. Pause function: The S1Ca can be stopped by remote control via the external control terminal. The pause function operates only via the external control terminal. The following functions are activated by keystrokes: Stop function: The S1Ca can be stopped by pressing the STOP/START key without disconnecting from the mains power supply. Prime function: Priming (short term feed at maximum frequency) is activated by pressing both arrow keys at the same time (in stroke rate permanent display). ProMinent Page 35

57 Features of the S1Ca metering pumps Dulcodes UV-Desinfektionsanlage Optional relay The S1Ca has two connection options. Fault indicating relay or power relay option: In the event of fault signals, warning signals or float switch activation signals, connects an electrical circuit to trigger alarm sirens etc. The relay is retrofitted via an aperture in the power end. Fault indicating and pacing relay option: In addition to the fault indicating relay the pacing relay can make a contact with every stroke. The relay is retrofitted via an aperture in the power end. Function and error indicators LCD indicator The operating and error status is shown via the three LEDs and the error indicator on the LCD (see also section 9): If a fault occurs error will appear along with an additional fault warning. LED indicator Operating indicator (green) This indicator is lit as long as the S1Ca is operating correctly. It goes out briefly with every stroke. Warning indicator (yellow) This warning light appears if the S1Ca electronics detect a situation that could lead to a fault, e.g. liquid levels low 1st stage. Error indicator (red) This warning light appears if a fault occurs, e.g. liquid levels low 2nd stage. Hierarchy of operating modes, functions and fault statuses The different operating modes, functions and fault statuses each have a differing effect on whether and how the S2Ca functions. These effects are given below: 1. Prime 2. Fault, stop, pause 3. Auxiliary frequency 4. Manual, analogue, contact, batch i.e. 1. Prime can be activated in stroke rate permanent display in any pump status (as long as it is operable) 2. Fault, stop and pause stop all system parts up to prime. 3. The stroke rate of the auxiliary frequency always overrides the stroke rates of the operating modes listed in point 4. Page 36 ProMinent

58 Dulcodes UV-Desinfektionsanlage Features of of the the S1Ca S2Ca metering pumps 5.3 Sockets, symbols and wiring diagram Fig. 16 (1) Socket for two-stage float switch with advance warning and de-activate function (with function plug*, not illustrated) (2) External socket for contact or analogue controller with zero volts deactivation via pause function (with function plug* - not illustrated) (3) Metering monitor socket for connection of ProMinent metering monitor (4) Mains switch (1-pin) (5) Relay cable (fault indicating or pacing relay) (6) Socket for diaphragm rupture sensor (7) Mains lead with plug *Must be plugged in unless cable attached yellow/no green/nc white/no brown/c green/nc white/no brown/c fault indicating relay pacing relay Technical data, relay (control version) Pump type S1Ca Relay Fault-indicating relay Fault-indicating relay + pulse generator Relay type Fault-indicating relay pulse generator Fault-indicating relay Voltage, max: 250 V 50/60 Hz 24 V DC 24 V 50/60 Hz Current, max. 2 A (ohmic) 100 ma 100 ma Hook up duration 100 ms Behaviour see Identcode see Identcode see Identcode Service life > cycles* > 50 x 10 6 (10 V 10 ma) > cycles Relay type Voltage, max: Current, max. Hook up duration Behaviour Service life Power relay * in the case of nominal load The contacts are zero volt. 250 V 50/60 Hz 16 A (ohmic) see Identcode > switching cycles N/C fault indicating relay - the relay closes immediately after the power is switched on and opens in the event of a fault. N/O fault indicating relay, the relay closes in the event of a fault. Use suitable interference suppression (e.g. RC glands) when connecting inductive loads. ProMinent Page 37

59 Features of the S1Ca metering pumps Dulcodes UV-Desinfektionsanlage Wiring diagram View of cable connectors from front Float switch cable for Universal signal cable (5-score) for 2 blue/alarm 1 black GND 3 brown pause Blue and black open -> alarm signal Brown and black open -> alarm signal + pump stops Metering monitor cable for Pause function: brown and black closed -> pump metering brown and black open -> alarm + pump stopped External/contact: white and black closed -> start contact for pump (note pause function: brown and black closed) Analogue: blue, black -> analogue output 0/4-20 ma (note pause function: brown and black closed) Auxiliary frequency: grey and black closed -> pump metering at pre-set stroking rate Circuit examples see p. 41 Diaphragm rupture cable for External/contact cable (2 core) for 2 blue/alarm 1 black/gnd 2 brown 4 white 1 brown / pause 2 white/cod 3 blue / analogue 4 black/ GND 5 grey/auxiliary 1 brown / 5 V 2 white/cod 3 blue 4 black/ GND Contact open -> alarm -> pump stops with controller type 0 Contact closed -> metering stroke Page 38 ProMinent

60 Dulcodes UV-Desinfektionsanlage Features of of the the S1Ca S2Ca metering pumps Technical data, external contact Semi-conductor switch elements (e.g. transistors in open-collector circuits) or contactors (relays) with a residual voltage of -0.7 V can be used as input switch elements. Controller type 0 (see identity code) Pin 1 = Pause input (activating function) Voltage at open contacts: approx. 5 V Input resistance: 10 kω Controller: zero volts contact (approx. 0.5 ma) semi-conductor (residual voltage: < 0.7 V) Pin 2 = Contact input Voltage at open contacts: approx. 5 V Input resistance: 10 kω Controller: zero volts contact (approx. 0.5 ma) semi-conductor (residual voltage: < 0.7 V) Min. contact duration: 20 ms Max. pulse frequency: 25 pulses/s Pin 3 = unused Pin 4 = GND Pin 5 = Auxiliary input Voltage at open contacts: approx. 5 V Input resistance: 10 kω Controller: zero volts contact (approx. 0.5 ma) semi-conductor (residual voltage: < 0.7 V) Controller type 1 (see identity code) Pin 1 = Pause input (activating function) Voltage at open contacts: approx. 5 V Input resistance: 10 kω Controller: zero volts contact (approx. 0.5 ma) semi-conductor (residual voltage: < 0.7 V) Pin 2 = Contact input (not active during analogue operation) Voltage at open contacts: approx. 5 V Input resistance: 10 kω Controller: zero volts contact (approx. 0.5 ma) semi-conductor (residual voltage: < 0.7 V) Min. contact duration: 20 ms Max. pulse frequency: 25 pulses/s Pin 3 = Identical to input* Input load: approx. 120 Ω Pin 4 = GND Pin 5 = Auxiliary input Voltage at open contacts: approx. 5 V Input resistance: 10 kω Controller: zero volts contact (approx. 0.5 ma) semi-conductor (residual voltage: < 0.7 V) * The metering pump makes its first metering stroke at approx. 0.4 ma (4.4 ma) and starts continuous operation at approx ma. ProMinent Page 39

61 Features of the S2Ca S1Ca metering pumps Dulcodes UV-Desinfektionsanlage Block circuit diagram S1Ca Inputs Outputs Empty signal, warning 3 brown/pause 2 blue/alarm 1 black/gnd Level monitor Pump, Inside Metering monitor Flow control Diaphragm rupture sensor 1 brown/5 V 2 white/cod 3 blue 4 black/gnd 2 blue/alarm 1 black/gnd Metering monitor Diaphragm rupture sensor Fault indicating relay Fault indicating and pacing relay VDE cable: 2 green/nc 1 white /NO 4 brown/c VDE cable: 1 yellow/no (fault) 4 green/c (fault) 3 white/no (pacing) 2 brown/c (pacing) 3 blue/analogue Circuit examples overleaf 2 white/contact 1 brown/pause 4 black/gnd 5 grey/auxiliary External activation GND Mains Page 40 ProMinent

62 Dulcodes UV-Desinfektionsanlage Features of of the the S1Ca S2Ca metering pumps Circuit examples: universal signal cable by customer Cable Pump, inside External contact function (ProMinent external/contact cable) two-core 2 white/contact 4 brown/gnd External activation Pulse rate, e.g. contact water meter External contact function (ProMinent universal signal cable) five-core 3 blue/analogue 2 white/contact 1 brown/pause 4 black/gnd 5 grey/auxiliary External activation Pulse rate, e.g. contact water meter Pause function 3 blue/analogue 2 white/contact 1 brown/pause 4 black/gnd 5 grey/auxiliary External activation Permanent contact, e.g. from control room Auxiliary frequency function 3 blue/analogue 2 white/contact 1 brown/pause 4 black/gnd 5 grey/auxiliary External activation External analogue function Permanent contact, e.g. from control room 0/4-20 ma 3 blue/analogue 2 white/contact 1 brown/pause 4 black/gnd 5 grey/auxiliary External activation Analogue signal, e.g. from magnetic inductive flow meter ProMinent Page 41

63 Features of the S2Ca S1Ca metering pumps Dulcodes UV-Desinfektionsanlage IMPORTANT The universal signal cable, the external/contact cable and the level monitor cable should not be less than 1.20 m long, otherwise cable recognition will fail. 5.4 Retrofitting relays (not by PROFIBUS version) Delivery range: 1 relay circuit set with 2 screw fasteners 1 relay cable set with socket 1 seal Press-out relay opening WARNING Disconnect the S1Ca from the mains power supply and rinse liquid end before commencing work (see section 10)! IMPORTANT When preparing the opening, ensure that the punch is not forced through the entire pump base! Pump circuits may become damaged. Place the S1Ca on a firm surface with the relay opening press-out section at the top (see fig. 17) Place a punch (dia mm) in the centre of the relay opening press-out section, and strike briefly and sharply with a hammer (approx. 250 g) If necessary clean up the edges of the opening Remove the pressed out section from the S1Ca Inserting the relay component Hold the relay component with your right hand gripping the left and right hand edges of the relay cover, and tilt the front end slightly to the left (see fig. 18) Push the relay component through the relay opening, holding the upper corner of the lower edge against the guide rail on the pump base, until the contact of the relay component has reached the controller contact. (test: can you still move the end of the circuit back and forth?) Gently push the relay component right into the opening Screw the relay cover firmly onto the housing using the screws provided Insert the relay cable plug seal into the relay cover and screw on the plug (see fig. 20) The pump is generally programmed ex-factory to drop-out action alarm relay and if fitted pull-up action clock pulse generator relay. If a switching function is required, the pump can be reprogrammed at the Heidelberg plant (not necessary for PROFIBUS -version). Fig. 17 Fig. 18 Page 42 ProMinent

64 Dulcodes UV-Desinfektionsanlage Features of the S1Ca metering pumps / Control elements Fig. 19 Fig Control elements Please acquaint yourself with the S1Ca control elements with the help of the control elements and key functions overview! Indicators The LCD display supports the operation and setting of the S1Ca with a range of indicators: Stop Aux Pause Error Mem Calib Flow Set The indicators are interpreted as follows: Symbol for P key: The S1Ca is in settings mode. Close symbol: In a continuous display: lock (if code has been set). In settings mode: indicates access to code menu. Stop: The S1Ca has been stopped using the STOP/START key. Aux: The S1Ca is pumping at the auxiliary frequency. In AUX menu: the S1Ca is in the AUX menu. Pause: The S1Ca has been stopped using the pause function (external). Error: A fault has occurred and the pump has been stopped. Mem: An additional memory function has been set in the contact and batch operating modes. In CNTCT or BATCH menus ( mem flashes): the memory function can be set. Calib: The S1Ca is in the CALIB menu. In a continuous display ( calib flashes ): Deviation from the stroking rate from the value at the time of the calibration by more than 10 percent (e.g. in the case of a stroke length of 40% when it has been set to less than 30% or more than 50%). Flow: The S1Ca is in the FLOW menu. Set: The S1Ca is in the SET menu. Exclamation mark: The number of strokes reached is above the maximum value (99999) that can be shown in the LCD display. NOTE When calibrated, the S1Ca displays the feed rate and the feed capacity in l and/or in l/h or in gal and/or g/h. ProMinent Page 43

65 Settings Dulcodes UV-Desinfektionsanlage 7 Settings NOTE Open out the fold-out page following the title page fully! There you will find the overviews control elements and key functions and operating settings diagram. If no keys are pressed within a period of 1 minute, the S1Ca will return to a continuous display. Basic information for setting up the S1Ca Confirm entries Press the P key briefly; you will automatically move to the next menu option or to a continuous display. Exit menu option without confirming Press the P key for 3 s: The entry is cancelled and you will return to a continuous display. Incremental change Iof a value Press the i key 1x; you can toggle between altering the digits of a value ( change individual digits = standard) or incremental alteration of a value ( change a figure ). Change adjustable values Confirm adjustable values Press UP or DOWN arrow key; The flashing digit or figure will start to increase or decrease incrementally. For change individual digits : confirm each digit using the P key. When the last digit has been confirmed you will automatically move to the next menu option or to a continuous display. For change a figure ; press the P key 1x; you will simultaneously move to the next menu option or to a continuous display. Correct wrongly set digits Press the i key 2x; you will go back to the first digit. Page 44 ProMinent

66 Dulcodes UV-Desinfektionsanlage Settings 7.1 Check adjustable values Before setting up the S1Ca you can check the current settings of adjustable values: Press the i key ( i as in info ) when the S1Ca is in continuous display mode (There is no P key symbol in the LCD display). Each time you press the i key you will see a different continuous display. The number of continuous displays depends upon the identity code, the selected operating mode and the connected accessories (see overview continuous displays ). 7.2 Change to settings mode If you hold down the P key for 2 seconds in any continuous display, the S1Ca will change to the settings mode. If CODE 1 is set, the code must be entered after pressing the P key. The following menu options appear first in the settings mode (see also overview operating/ settings diagram ): MODE menu CODE menu (optional) SET menu CLEAR window In order to adapt the S1Ca to your process requirements you must: 1. Select the operating mode in the MODE menu. 2. If necessary enter the settings for this operating mode in the SET menu. IMPORTANT Note the following diagram! 1. MODE menu Continuous display 2 s P 2. CODE menu SET menu CLEAR window 7.3 Select operating mode (MODE menu) The following operating modes are selected via the MODE menu (depending upon identity code, some operating modes may be absent): Manual: for operation by hand (Identity code, control variant: manual, standard option) Analogue: for electronic control (Identity code, control variant: analogue current) Contact: for contact operation (Identity code, control variant: external 1:1 / external with pulse control) ProMinent Page 45

67 Settings Dulcodes UV-Desinfektionsanlage Batch: for batch operation (Identity code, control variant: external with pulse control) Analog - ANALOG Manual - MANUAL Analog Manual Contact Batch P P Contact - CONTACT Batch - BATCH Continuous display 7.4 Settings for operating mode (SET menu) Exceptions: Timer and PROFIBUS NOTE First select the operating mode in the MODE menu! Exceptions: Timer and PROFIBUS. In the SET menu you can adjust various settings depending upon the selected operating mode. The following programmable function settings menus appear in all operating modes: Calibrate (CALIB menu) Auxiliary frequency (AUX menu) Flow (FLOW menu, available only if flow monitor is connected) See also section 7.5! Further settings menus depend upon the selected operating mode Settings for manual operating mode There are no other settings menus in the overall SET menu for the manual operating mode apart from those described in Settings for analogue operating mode (ANALG menu) In addition to those settings menus described in 7.5, there is an additional ANALG menu in the overall SET menu for the analogue operating mode. The stroke rate is controlled by an analogue electrical signal via the external control terminal. You can select three signal-processing methods: 0-20 ma: at 0 ma the S1Ca does not operate at 20 ma the S1Ca operates at 180 strokes/min. Between these two extremes the stroke rate is proportional to the electrical signal. Page 46 ProMinent

68 Dulcodes UV-Desinfektionsanlage Settings 4-20 ma: at 4 ma the S1Ca does not operate at 20 ma the S1Ca operates at 180 strokes/min. Between these two extremes the stroke rate is proportional to the electrical signal. For signals of below 3.8 ma a fault will be detected and the S1Ca will stop (e.g. cable break). Curve: In the curve processing mode you can programme the S1Ca ratios. There are 3 options available: = straight line = lower band = upper band Straight line: The following symbol appears in the LCD display:. You can enter any stroke frequency ratio for the S2Ca in proportion to the electrical signal. You must enter two points P1 (I1, F1) and P2 (I2, F2). F1 is the stroke rate at which the pump should operate at current I1: the straight line and the ratio are fixed accordingly: Fmax F2 P2 F1 P1 0 I 1 I 2 20 I [ma] Fig. 21 NOTE Draw a diagram like the one above - with values for (I1, F1) and (I2, F2) - in order to set the S1Ca to your required stroke rate! ProMinent Page 47

69 Settings Dulcodes UV-Desinfektionsanlage Lower/upper band: This processing mode allows you to control a pump via an electrical signal as shown in the diagrams below. Lower band e.g. Alkali pump Upper band e.g. acid pump Fmax Fmax F1 P1 F2 P2 F2 P2 F1 P1 0 I 1 I 2 20 I [ma] 0 I 1 I 2 20 I [ma] Fig. 22 Fig. 23 Lower band: The symbol appears in the LCD display. The S1Ca will operate below I1 at F1. Above I2, the S1Ca ceases to operate. Between I1 and I2 the stroke rate is between F1 and F2, proportional to the signal current. Error processing Upper band: The signal appears in the LCD display. The S1Ca will cease to operate below I1. Above I2, the S1Ca will operate at F2. Between I1 and I2 the stroke rate between is F1 and F2, proportional to the signal current. The smallest processable difference between I1 and I2 is 4 ma. In the ER (error) menu option you can activate an error processing function for the curve mode. An error message appears for signals below 3.8 ma and the S1Ca stops Settings for contact operating mode (CONTCT menu) In addition to those settings menus described in 7.5, there is an additional CONTCT in the overall SET menu for the contact operating mode. The operating mode contact allows you to activate a single stroke or a series of strokes. The strokes can be activated by a pulse or via the external control terminal. This operating mode is intended to transfer input pulses into a reduction (fraction) or small increase in strokes. IMPORTANT The factor resets to 1 if you change to a different operating mode. Page 48 ProMinent

70 Dulcodes UV-Desinfektionsanlage Settings In the contact - identity code: external with external pulse control you can enter the number of pulses after which a stroke should be carried out. Contact - identity code: external with external pulse control is intended for small dosing quantities. The number of strokes per pulse depends upon the factor, which you can enter. This allows you to vary to a certain extent the input pulses by a factor of 1.01 to and/or reduce by a factor of 0.01 to 0.99: Number of strokes activated = factor x number of input pulses Examples Factor Pulse (sequential) Stroke number (sequential) Increase (1 / 2) (1 / 1 / 1 / 2) Reduction (3 / 2) (1 / 1) (2 / 1 / 1) (1 / 1 / 1) Explanation of increase At a factor of 1 For every 1 pulse, 1 stroke is activated At a factor of 2 For every 1 pulse, 2 strokes are activated At a factor of 25 For every 1 pulse, 25 strokes are activated Explanation of decrease At a factor of 1 After 1 pulse, 1 stroke is activated At a factor of 0.5 After 2 pulses, 1 stroke is activated At a factor of 0.1 After 10 pulses, 1 stroke is activated At a factor of 0.75 After 2 pulses, 1 stroke is activated, then after 1 pulse, 1 stroke is activated, then after 2 pulses, 1 stroke is activated etc. NOTE If a remainder occurs when the factor is processed, the S1Ca counts up the remainder values. When the sum reaches or exceeds 1 the S1Ca will activate a stroke. This ensures that the stroke number corresponds exactly to the factor throughout the dosing operation. The number of input pulses which have not been processed are stored by the S1Ca in the stroke memory. When the STOP/START key is pressed or the pause function is activated, the stroke memory is deleted (this can be avoided using the memory extension function, see below). You can optimally adapt the S1Ca to the respective process, e.g. in connection with contact water meters. ProMinent Page 49

71 Settings Dulcodes UV-Desinfektionsanlage Memory extension function The memory extension function can be optionally activated ( mem appears in the LCD display). When Memory is activated the S1Ca adds any strokes which could not be carried out up to the maximum capacity of the stroke buffer strokes. If this maximum capacity is exceeded the pump will register a fault Settings for batch operating mode (BATCH menu) In addition to those settings menus described in 7.5, there is an additional BATCH menu in the overall SET menu for the batch operating mode. The batch operating mode is a variant of the contact operating mode (see 7.4.3). You can pre-select a stroke number (no breaks, whole numbers only from 1 to 65535) as well as a feed quantity (batch). To switch between entries for stroke number and feed quantity press the i key 1x in the corresponding menu option (see also overview operating/settings diagram, fold-out page). The batch operating mode is intended for large dosing quantities. Metering can be actuated by pressing the P-key or via a pulse from the external control socket. The number of input pulses which have not been processed are stored by the S1Ca in the stroke memory. The stroke buffer is limited to the batch size when memory is not activated (- with Memory at stokes). You can delete it by switching to a different operating mode. Memory extension function The memory extension function can be optionally activated ( mem appears in the LCD display). When Memory is activated the S1Ca adds any strokes which could not be carried out up to the maximum capacity of the stroke buffer strokes. If this maximum capacity is exceeded the pump will register a fault. 7.5 Settings for programmable functions (SET menu) The following programmable function settings menus appear in all operating modes: Calibrate (CALIB menu) Auxiliary frequency (AUX menu) Flow (FLOW menu, available only if flow monitor is connected) Settings for calibration function (CALIB menu) P Page 50 ProMinent

72 Dulcodes UV-Desinfektionsanlage Settings The S1Ca can also run in calibration mode. The corresponding continuous displays show the current dosing quantities or the feed rate. The calibration is retained in the event of a change of the set stroke length by up to ± 10 percent (if the stroke length is set to 40% the range is 30% to 50%). If the stroke length is changed by more than ± 10 percent the yellow warning light lights up, the permanent display flashes and the flashing Calib indicator appears. NOTE Do not go below 30 % stroke length (SEK type: 50 %). This will significantly affect accuracy of calibration. Calibration becomes increasingly accurate the more strokes made by the S1Ca during calibration (recommended: at least 200 strokes). WARNING If using a hazardous feed chemical, the following setting instructions ensure adequate safety precautions have been taken! Calibration Insert the suction tube into a measuring cylinder containing the feed chemical - the discharge tubing must also be correctly installed (operating pressure,!) Suck up the feed chemical (press both arrow keys at the same time) when the suction tube is empty Note the liquid level in the measuring cylinder and the stroke length Select the CALIB menu and go the first menu option using the P key Select ON using an arrow key and change to the next menu option using the P key To commence calibration, press the P key. The S1Ca starts to pump and displays the number of strokes ( STOP appears at regular intervals) After a sufficient number of strokes, stop the S1Ca with the P key Calculate the dosed quantity (difference between the original quantity and the quantity remaining) Enter this quantity in the next menu option and then change to the following menu option by pressing the P key. Select the unit ( L or gal ) in the UNIT menu with an arrow key and press the P-key. The S1Ca is calibrated. The corresponding continuous displays show the calibrated values. The total stroke number and total litres are set during calibration to 0. The S1Ca is in the STOP status Settings for auxiliary frequency function (AUX menu) The programmable function auxiliary frequency allows switching to a different stroke frequency, which can be set in the AUX menu. It can be activated via the external control terminal. When the auxiliary frequency is activated, aux appears in the LCD display. This auxiliary frequency overrides the current stroke frequency set for the selected operating mode. ProMinent Page 51

73 Settings Dulcodes UV-Desinfektionsanlage Settings for the flow function (FLOW menu) The flow menu only appears when a dosing monitor is connected to the dosing monitor terminal. This dosing monitor registers each discharge stroke of the S1Ca at the discharge connector and transmits it back to the S1Ca. If this response transmission is serially omitted for a period set in the FLOW menu (due to failure or below-minimum dosing) the S1Ca stops. 7.6 Setting code (CODE menu) The code menu is used to select whether you want to prevent access to parts of the settings options. In the first menu option you can choose CODE 1 or CODE 2 (both use the same number). Select CODE 1 to prevent access to the settings mode (➀ in the overview operating/ settings diagram, fold-out page). In the next menu option, enter the number you wish to use as the code. Select CODE 2 to prevent access to the settings options for directly alterable values in the continuous displays (➁ in the overview operating/settings diagram, fold-out page). In the next menu option, enter the number you wish to use as the code. Select NONE to remove a pre-set security lock. 7.7 Cancel total stroke number or total litres (CLEAR window) In the CLEAR window you can delete the stored total stroke number and simultaneously the total litres (= set to 0 ). You may then press the P key briefly to exit this window. The values displayed are counted incrementally from the point of commissioning the pump, or from the last delete action. Page 52 ProMinent

74 Dulcodes UV-Desinfektionsanlage Operating 8 Operating This section describes all operating options available to you when the S1Ca is in continuous display mode (no P key symbol in the LCD display). NOTE Open out the fold-out page following the title page fully! There you will find the overviews control elements and key functions and operating/settings diagram. Look at the overview continuous displays. This page shows you which displays are available in which operating mode, and which values are directly alterable in the corresponding continuous displays. 8.1 Manual operation Set stroke length Stroke length is continually adjustable within a range of %. The recommended stroke length range, which will practically guarantee technical reproducibility, is % (SEK type: %). NOTE At low stroking rates (less than 1/3 maximum stroking rate) the controller switches to digital stroking mode. This ensures adequate cooling of the motor at low stroking rates. Stop/Start S1Ca Start batch Load factory settings Change to settings mode Check adjustable values Change directly alterable values Stroke rate Feed rate Factor Display program version The following operating options are available via the different keys (see also figure on the next page): To stop S1Ca: press STOP/START key. To start S1Ca: press STOP/START key. Press the P key briefly in batch operating mode. Press the P key for 15 s to load factory calibration settings! Current settings will be deleted. WeIf you press the P key for 2 s in any continuous display the S1Ca will change to settings mode (see section 7). If CODE 1 is set, the code must be entered after pressing the P key. Each time you press the i key you will see a different continuous display. The number of continuous displays depends upon the identity code, the selected operating mode and the connected accessories. To change a value (see below) directly in the corresponding continuous display, press one of the arrow keys until set appears in the LCD display. The delay has been programmed in to prevent inadvertent changing of values. If CODE 2 has been set, this code must be entered after pressing the arrow key. Directly alterable values are as follows: In manual, contact and batch operating modes: The stroke rate can be altered in the stroke rate display. In manual operating mode The feed rate can be altered in the feed rate display. The factor is the number of strokes activated by an external pulse or a press of the P key (in batch mode only). In Batch operating mode: You can alter the factor from the remaining strokes display. The S1Ca returns to the original continuous display a few seconds after the factor has been reset. Press the P key for 10 seconds to display the program version. Example: V X1010. In the case of LOAD3 release the key immediately! ProMinent Page 53

75 Operating / Troubleshooting Dulcodes UV-Desinfektionsanlage Batch size Priming Cancel error In batch operating mode: The batch size can by changed from the batch size/remaining litres display. The S1Ca returns to the original continuous display a few seconds after the batch size has been reset. The priming function is activated by pressing both arrow keys at the same time. Error messages are cancelled by pressing the P key briefly. Continuous display STOP START Stop/start pump 2 Change directly alterable values Prime P P i Start batch (in "batch" operating mode only) Cancel error Check adjustable values P 2 s 1 Settings mode 1 2 = Security lock (CODE 1) = Security lock (CODE 2) 8.2 Remote control Remote control of the S1Ca is possible via a control cable or PROFIBUS (see Section 5.3 and Chapter 7, Supplementary instructions for ProMinent gamma/ L and ProMinent Sigma versions with PROFIBUS as well as your plantdocumentation). 9 Troubleshooting WARNING EX-pump only: metering pumps and their peripheral equipment must be serviced by specially trained or authorised personnel! Always take suitable precautions when using hazardous chemicals! Ensure the equipment is de-pressurised before working on the pump! Cause Remedy Cause Remedy Pump primes despite completed stroke action and no venting Crystalline deposits on the ball seat because valves have dried out. Remove the suction sleeve from the chemical supply container and rinse out the liquid end thoroughly. If still unsuccessful, dismantle valves and clean. Fluid is seeping from the top plate The liquid end is not sealed against the pump diaphragm. Tighten screws in the liquid end. If unsuccessful, replace the diaphragm (see section 4.3). Page 54 ProMinent

76 Dulcodes UV-Desinfektionsanlage Troubleshooting Green LED indicator (operating display) is not lit Cause Incorrect or no mains voltage. Remedy Use the recommended mains voltage as given in the voltage specification on the nameplate. Error Messages Red LED display is lit, Error and MINIM flash in the display Cause Fluid level in the chemical storage tank has reached liquid level low, stage 2. Remedy Fill the chemical supply container. Red LED display is lit, Error and ANALG flash in the display Cause S1Ca is in analogue operating mode, a fault routine has been programmed in the ANALG menu and the operating current has fallen below 3.8 ma. Remedy Remedy low operating current. Switch fault routine OFF (see section ). Red LED display is lit, Error and CNTCT flash in the display Cause S1Ca is in contact or batch operating mode and the extended function memory has been set. In addition a very large factor has been entered, too many contacts have been input or the P- key has been pressed too often, resulting in an overflow of the stroke memory. Remedy Press the P-key, saved data will be deleted. Change S1Ca set up. Red LED display is lit, Error and FLOW flash in the display Cause Dosing monitor not properly connected. Remedy Connect dosing monitor properly. Press P-key. Cause Dosing monitor has reported more defective strokes than have been set in the FLOW menu. Remedy Press P-key. Investigate the cause and remedy. Red LED is lit. Error appears in the display and MOTOR is flashing Cause The motor is not operating accurately because the backpressure is too high. Remedy Reduce backpressure. Press the P key (reset key). Cause The motor is overheating. Remedy Check ambient temperature (max. 40 ºC). Allow motor to cool down. Press the P key (reset key). Cause Other motor fault. Remedy Call ProMinent. Press the P key (reset key). Red LED is lit. Error appears in the display and TEMPERATURE is flashing Cause The temperature in the pump housing is too high because the ambient temperature is too high. Remedy Reduce ambient temperature. Allow motor to cool down. Press the P key (reset key). Cause The temperature in the pump housing is too high because the pump is consuming too much power. Remedy Check installation, rectify if necessary. Allow motor to cool down. Press the P key (reset key). ProMinent Page 55

77 Troubleshooting / Decommissioning and disposal Dulcodes UV-Desinfektionsanlage Cause Remedy Cause Remedy Cause Remedy Red LED display is lit, Error appears in the display and FAN is flashing Fault related to fan in pump housing. Check fan and replace if necessary. Press the P key (reset function). Red LED display is lit, Error appears in the display and SYSTEM is flashing Controller fault. Disconnect the pump from the mains and reconnect. If the error message continues, send the pump back to ProMinent. Red LED lights up, Error appears in the display and Menu flashes. Stroke buffer full Rectify fault Press P key (Make a note of what effect this has on your process). All other Errors Please contact your ProMinent branch or representative! Fault Signals Yellow LED display is lit Cause Liquid level in chemical storage tank has reached liquid level low, stage 1. Remedy Fill chemical storage tank. Cause Remedy Yellow LED Display is lit and calib flashes The pump is calibrated and the stroke length deviates by more than ±10 % from the value at the time of calibration. Reset the stroke length or calibrate the pump again to the desired stroke length. 10 Decommissioning and disposal Decommissioning WARNING EX-pump only: metering pumps and their periphery must be maintained or decommissioned by qualified or authorised personnel. For all metering pumps for metering inflammable media applies: starting up and emptying only supervised by a competent person. When decommissioning the pump, ensure that all dirt and chemicals are cleaned from the housing and particularly the liquid end. Always take suitable precautions when using hazardous chemicals! Ensure that the equipment is de-pressurised! Disconnect the pump from the mains. Empty the liquid end by placing the pump on its head and allowing the chemical to drain out. Rinse the liquid end with a suitable material, thoroughly rinse the liquid end after use with hazardous materials! If decommissioning is only temporary, maintain the correct storage conditions: Storage temperature: -10 to +50 C Air humidity: < 92 % relative humidity Disposal WARNING Spring under tension! Take particular care when disassembling the pump as the return spring (Item 5, Chapter 2.2) is under considerable mechanical tension! IMPORTANT Observe your locally applicable regulations (particularly with regard to electronic scrap)! Page 56 ProMinent

78 Dulcodes UV-Desinfektionsanlage Spare parts and accessories 11 Spare parts and accessories CAUTION The assembly and installation of ProMinent metering pumps with other-make parts that are not tested and recommended by ProMinent are not permitted and can lead to personal injury and damage to property for which no liability shall be accepted! Spare parts You will find the order numbers for the wearing parts in the exploded view drawings in the annex. If you require further parts, please order the Spare parts list ProMinent Sigma/ 1. Actuator for automatic stroke adjustment, setting time approx. 1 sec for 1% stroke length, feedback potentiometer 1k Ohm enclosure rating IP 54. Adjuster comprising actuator and incorporating servo controller for stroke length adjustment via standard signal. Standard signal inpu t 0/4-20 ma, corresponds to stroke length %. Manual to automatic mode switch, switch for stroke length adjustment in manual mode, mechanical position display of 0/4-20 ma actual stroke length value output for remote display. Variable speed motors with integrated speed changer (Identcode characteristic V) Power supply 1 ph 230 V, 50/60 Hz, 0.09 kw Optional external control via 0/4-20 ma Speed controllers in metal casing (Identcode characteristic Z) The speed controller kit comprises a speed changer and a 0.09 kw variable speed motor. Float switches 2-stage, with 2 m connection cable Alarm relays For signalling faults Alarm and clock pulse generator relays For cyclic timing of other devices and for signalling faults. Control cables Universal control cable 5-core/2.5 and 10 m External contact cable 2-core/2.5 and 10 m Foot valves With intake filter and non-return ball for connection at end of intake line. Metering valves With spring-loaded non-return ball for metering in open or closed systems and for mounting the metering line. Backpressure valves For exact metering at low operating pressure or as overflow safety valve. Accumulators For pulsation damping in long metering lines. Metering monitors For monitoring metering operations. After an adjustable number of non-acknowledged metering strokes, a fault is indicated and the metering pump shut down. Intake assemblies With foot valve and float switch for expendable packing drums or metering tanks. Metering tanks From 35 to 1000 l capacity with lockable screw cover and necessary accessories. Manual/electric stirrers For mixing and preparing metering solutions. ProMinent Page 57

79 Motor data sheet Dulcodes UV-Desinfektionsanlage Motor Datenblatt / Motor data sheet / Fiche technique pour moteur Bestell Nr Hersteller Bonfiglioli order no. / no. de commande producer / producteur Motor-Typ M2V A56B4 Leistungsfaktor 0,62/0,66 motor type power factor type du moteur facteur de puissance Maschinenart 3-Ph. Motor Wirkungsgrad 55,5 % type of machine efficiency désignation rendement Schutzart IP55 Bemessungsfrequenz 50/60 Hz degree of protection rated frequency degré de protection fréquence nominale Bauform IMV1 Bemessungsdrehzahl 1370/1630 U/min mounting rated speed rpm construction vitesse nominale t/mn Bemessungsleistung 0,09 kw Wärmeklasse F rated output temperature class puissance nominale class d isolement Bemessungsspannung / Anzugsstrom 2,6 fach rated voltage 400/230 V starting current fold tension nominale courant de démarrage fois Bemessungsstrom 0,39/0,70 (50 Hz) A Anzugsmoment 1,8 fach rated current 0,38/0,68 (60 Hz) A starting torque fold courant nominale couple de démarrge fois Geprüft nach ICE 34-1 Kippmoment 1,9 fach tested in acc. with pull-out torque fold contrôlé selon couple de décrochage fois PTB Nr. ohne EX-Schutz Umgebungstemperatur max. 40 C without EX-protection ambient temperature température ambiante Schaltung connection branchement / Anmerkung 400/230 V Nr :1 comments / V (50 Hz) Nr :1 observation / V (60 Hz) Nr :1 These gear motors are available with the above transmissions. ProMinent Pumpentyp S1Ba _ S _ S1Ca _ U _ ProMinent Dosiertechnik GmbH Heidelberg Germany Nr./No. MD Datum/Date Motor datasheets are available for further information. Special motors and special motor flanges are possible on request. Page 58 ProMinent

80 Dulcodes UV-Desinfektionsanlage EC Declaration of Conformity For pumps without Ex protection: For pumps with Ex protection: The EC conformity declaration for the pump for explosion-threatened workplaces is supplied with the pump. The EC conformity declarations, the EC series prototype test reports and the operating manuals for the individual components are also supplied with the pump. ProMinent Page 59

81 Exploded diagrams of liquid ends Dulcodes UV-Desinfektionsanlage Delivery unit Sigma/ PVT for identity code types: 12035, 12017, Delivery unit Sigma/ PVT for identity code types: 07065, 10044, Valve assy DN 10/PVT* Order No Spring ** Ball * Ball seat * Diaphragm FM 050 Order-No Diaphragm FM 065 Order-No Valve assy DN 10/PVT* Order No Spare parts kit FM 50 PVT Order No Spare parts kit FM 65 PVT Order No * The listed items are constituent parts of the spare part kit. ** Special accessories (not included in spare part kit) Subject to technical modifications. Abb _05-104_00_99-03_2 Page 60 ProMinent

82 Dulcodes UV-Desinfektionsanlage Exploded diagrams of liquid ends Delivery unit Sigma/ PVT for identity code types: 04084, 04120, Valve assy DN 15/PVT* Order No Valve spring * Valve ball * Ball seat * Diaphragm FM 120 Order No Valve assy DN 15/PVT* Order No Spare parts kit FM 120 PVT Order No * The listed items are constituent parts of the spare part kit. Subject to technical modifications. Fig _05-104_00_99-03_2 ProMinent Page 61

83 Exploded diagrams of liquid ends Dulcodes UV-Desinfektionsanlage Delivery unit Sigma/ PVT ÜV-A for identity code types: 12035, 10050, Delivery unit Sigma/ PVT ÜV-A for identity code types: 07065, 10044, Delivery unit Sigma/ PVT ÜV-A for identity code types: 04120, 04084, Overflow valve assy 12 bar PVA Order No Overflow valve assy 10 bar PVA Order No Overflow valve assy 7 bar PVA Order No Overflow valve assy 4 bar PVA Order No For other spare parts see delivery unit without overflow valve (see p. 57 and p. 58). Subject to technical modifications. Fig _05-104_01_00-03_2 Delivery unit Sigma/ SST ÜV-A for identity code types: 12035, 12017, Delivery unit Sigma/ SST ÜV-A for identity code types: 07065, 10044, Delivery unit Sigma/ SST ÜV-A for identity code types: 04120, 04084, Overflow valve assy 12 bar SSA Order No Overflow valve assy 10 bar SSA Order No Overflow valve assy 7 bar SSA Order No Overflow valve assy 4 bar SSA Order No For other spare parts see delivery unit without overflow valve (see p. 60 and p. 61). Subject to technical modifications. Fig _05-104_01_01-03_02 Page 62 ProMinent

84 Dulcodes UV-Desinfektionsanlage Exploded diagrams of liquid ends Delivery unit Sigma/ SST for identity code types: 12035, 12017, Delivery unit Sigma/ SST for identity code types: 07065, 10044, Spring ** Ball * Ball seat * Valve assy DN 10/SST* Order No Diaphragm FM 050 Order No Diaphragm FM 065 Order No Valve assy DN 10/SST* Order No Spare parts kit FM 50 SST without valve Order No Spare parts kit FM 50 SST without valve Order No Spare parts kit FM 65 SST without valve Order No Spare parts kit FM 65 SST without valve Order No * The listed items are constituent parts of the spare part kit. ** Special accessories (not included in spare part kit). Subject to technical modifications. Fig _05-104_00_99-03_02 ProMinent Page 63

85 Exploded diagrams of liquid ends Dulcodes UV-Desinfektionsanlage Delivery unit Sigma/ SST for identity code types: 04084, 04120, Valve spring ** Valve ball * Valve ball seat * Valve assy DN 15/ SST * Order No Diaphragm FM 120 Order No Valve assy DN 15/ SST * Order No Spare parts kit FM 120 SST without valve Order No Spare parts kit FM 120 SST with valve Order No * The listed items are constituent parts of the spare part kit. Subject to technical modifications. Fig _05-104_01_00_99-03_2 Page 64 ProMinent

86 Dulcodes UV-Desinfektionsanlage Exploded diagrams of liquid ends Retrofit kit double diaphragm S1Ba/S1Ca S1Ba Retrofit kit double diaphragm FM 050 Order No S1Ba Retrofit kit double diaphragm FM 065 Order No S1Ba Retrofit kit double diaphragm FM 120 Order No S1Ca Retrofit kit double diaphragm FM 050 Order No S1Ca Retrofit kit double diaphragm FM 065 Order No S1Ca Retrofit kit double diaphragm FM 120 Order No Lens Order No Diaphragm failure detector * * The listed items are constituent parts of the spare part kit. Subject to technical modifications. Fig _05-104_00_98-03_2 ProMinent Page 65

87 Wiring diagram Dulcodes UV-Desinfektionsanlage Stroke actuator wiring diagram Feedback signal ma Input signal ma PE N L Power supply Wiring diagram for stroke length adjuster Power supply P2 P1 N E V+ Sig Page 66 ProMinent

88 Motor Pump Spare Parts Sigma 1, 2, & 3 Complete liquid ends include pump head, valves, mounting screws, diaphragm and backplate. Clamping nuts and inserts are not included with complete liquid ends, complete valves or spare parts kits. Spare parts kits include: PVT Liquid ends SST Liquid ends 1 Diaphragm 1 Diaphragm 1 Suction valve 2 Valve balls 1 Discharge valve 1 Set of o-rings, complete 2 Valve balls (sleeve rings, ball seat rings) 1 Set of o-rings Valve Complete Material Liquid End Spare Parts Code Complete Kit Valve Complete Diaphragm 12017, 12035, with Liquid end FM 50 PVT SST SST* , 10044, with Liquid end FM 65 PVT SST SST* , 04084, with Liquid end FM 120 PVT SST SST* with Liquid end FM 130 PVT SST SST* , with Liquid end FM 130 PVT SST SST* , with Liquid end FM 350 PVT SST SST* with Liquid end FM 350 PVT SST SST* , , , with Liquid end FM DN 25 PVT SST SST* , , , with Liquid end FM DN 32 PVT SST SST* Liquid Complete Valve Complete End Material Liquid Spare Parts Suction Discharge Packing Version Code End Kit (Spare valves only) set Sigma HK 08 (For pump versions 32002, S , & 10006) 12.5 (For pump versions 14006, S , & 05016) 25 (For pump versions 07012, S , & 02534) 50 (For pump versions 04022, S , & 01264) product overview solenoid-driven metering pumps motor-driven metering pumps pump spare parts & accessories pump engineering specifications analytical instrumentation analytical sensors 4/21/ Accessories 133

89 Pump & Systems Accessories Accessory Kits product overview solenoid-driven metering pumps Accessory kits for alpha, concept PLUS, beta and gamma/l pumps with tube fittings, including 5 ft. (1.5 m) of suction tubing, 10 ft. (3 m) of discharge tubing, foot valve and injection valve. Tubing Size (in.) Material Suction Discharge (select to fit pump) Code Tubing Tubing Part No. 1/4 x 3/16 PCB/NPB/NP3 PE PE /4 x 3/16 PPE/PP1 PE PE /4 x 3/16 PPB PE PE /4 x 3/16 PCE/NPE PE PE /2 x 3/8 PCB/NPB/NP1/NP3/NP6 PVC PE /2 x 3/8 PPE/PP1 PVC PE /2 x 3/8 PPB/PP2/PP3 PVC PE PVC 1/2" x 3/8" suction tubing is pliable, allowing foot valve to sink. PE discharge tubing is rigid. Pressure ratings are: PVC: 7 psig PE: 100 psig. Tubing, foot valves and injection valves for TT and SS pumps are not available as kits and must be ordered as separate items. Profibus adapters motor-driven metering pumps pump spare parts & accessories pump engineering specifications analytical instrumentation analytical sensors Control Cables 5-pin, M12 x 1 to 9 pin., Sub D-plug, length approx. 11.8" (300 mm) Required for external control of ProMinent metering pumps including: beta gamma/ L delta Sigma/ 1 control Sigma/ 2 control Sigma/ 3 control Description Part No. Universal control cable, 5-wire, 6 ft. (2 m) Universal control cable, 5-wire, 15 ft. (5 m) Universal control cable, 5-wire, 30 ft. (10 m) (SEE DETAILED WIRING DIAGRAMS NEXT PAGE) Part No. Y-adapter 2 x M12 x 1 male/female, 9 pin, Sub-D plug Adapter 1 x M12 x 1 male, 9 pin, Sub-D plug /21/ Accessories

90 Pump & Systems Accessories Control Cable Diagrams Remote On/Off BROWN and BLACK wires must be connected together via an ON/OFF contact or shorted together. When the contact is closed between the BLACK & BROWN wires, the pump will run. When the contact is open, the pump will stop. Note: If ON/OFF control is the only control feature being used, WHITE, BLUE & GREY wires are not used and should be cut back. BROWN: Remote On/Off (+) BLACK: Common GREY: Auxiliary Frequency WHITE: Pulse (+) BLUE: Analog (+) Pulse Control Pulse control will allow the pump to run in proportion to a pulsing potential free contact closure. Note: BROWN and BLACK wires have to be connected together via an ON/OFF contact or shorted together. GREY wire is not used and should be cut back. BROWN: Remote On/Off (+) BLACK: Common GREY: Auxiliary Frequency WHITE: Pulse (+) BLUE: Analog (+) Analog Control (not available with beta metering pumps) Analog control runs in proportion to an analog signal such as 4-20 ma. Note: BROWN and BLACK wires must be connected together via an ON/OFF contact or shorted together. The BLACK wire is negative and the BLUE wire is positive. GREY wire is not used and should be cut back. BROWN: Remote On/Off (+) BLACK: Common GREY: Auxiliary Frequency WHITE: Pulse (+) BLUE: Analog (+) Auxiliary Frequency Auxiliary frequency will allow the pump to default to a predetermined stroking frequency regardless of which operating mode the pump is in. The pump defaults to this stroking frequency as long as a contact is closed between the black and grey wires of the universal control cable. Note: BROWN and BLACK wires must be connected together via an ON/OFF contact or shorted together. BROWN: Remote On/Off (+) product overview solenoid-driven metering pumps motor-driven metering pumps pump spare parts & accessories pump engineering specifications analytical instrumentation BLACK: Common GREY: Auxiliary Frequency WHITE: Pulse (+) BLUE: Analog (+) analytical sensors 4/21/ Accessories 139

91 Pump & Systems Accessories Calibration Columns Calibration columns Clear PVC calibration columns Dimension (inches) Threaded base, Threaded Cylinder size Fitting size A B removable top both ends B 100 ml 1/2" NPT ml 1/2" NPT ml 1/2" NPT ml 1/2" NPT ml 1" FNPT ml 1" FNPT ,000 ml 2" FNPT ,000 ml 2" FNPT Typical Application of Calibration Columns Column w/removable top Note: Top must be removed during calibration Column threaded both ends Note: If plumbed as shown, a vent hole must be drilled into the top of the calibration column product overview solenoid-driven metering pumps motor-driven metering pumps Borosilicate Glass calibration columns with Viton o-rings for Sulfuric Acid Applications Glass cylinder with acrylic outer shield and 1/2" (316 SS) or 3/4" (PVDF, PVC) thick end flanges. All cylinders are bolted together using stainless steel rods with Viton O-rings for the glass seal and Buna N O-rings for the acrylic seal. A C B Dimensions (inches) Cylinder size Fitting size A B C Part No. 100 ml 1/2" CPVC / ml 1/2" PVDF / ml 1/2" SS / ml 1/2" CPVC / ml 1/2" PVDF / ml 1/2" SS / ml 1/2" CPVC / ml 1/2" PVDF / ml 1/2" SS / ml 1/2" CPVC / ml 1/2" PVDF / ml 1/2" SS / ml 1" CPVC ml 1" PVDF ml 1" SS ml 1" CPVC ml 1" PVDF ml 1" SS pump spare parts & accessories pump engineering specifications analytical instrumentation analytical sensors Viton and HYPALON are registered trademarks of DuPont Dow Elastomers 4/21/ Accessories 155

92 ACCUDRAW Calibration Cylinders Polypropylene PVC PVC ACCUDRAW has been developed for the accurate calibration of metering pumps. Standard features include: translucent PVC has dual scale USGPH & ml chemical resistant PVC sizes ml break resistant POLY sizes ml threaded or socket POLY meets ISO standards colored graduations custom sizes and other materials and lettering (acrylic, glass) on request PRIMARY FLUID SYSTEMS INC. Call Toll Free Tel (905) Fax (905)

93 ACCUDRAW ACCUDRAW Sizing and Ordering Information Polypropylene Construction Size Conn. BC BTC BDC 100 ml 1/2" NPT AC#1-100 AC#2-100 AC# ml 1/2" NPT AC#1-250 AC#2-250 AC# ml 1/2" NPT AC#1-500 AC#2-500 AC# ml 1/2" NPT AC# AC# AC# ml 1.0" NPT AC# AC# AC# ml 1.0" NPT AC# AC# AC# BC = bottom connection only, open top BTC= bottom and top connections BDC= bottom connection and dust cover top Dimensional Information Polypropylene Construction Model Size (ml) Dev (ml) A (inches) B (inches) AC# AC# AC# AC# AC# AC# AC#2/AC# AC#2/AC# AC#2/AC# AC#2/AC# AC#2/AC# AC#2/AC# Installations Calibration Cylinders "For Accuracy That Counts" PVC Construction Size/Scale Conn BC BTC BDC 100 ml/ 1.6 GPH 1/2" NPT PV#1-100 PV#2-100 PV# ml/ 4 GPH 1/2" NPT PV#1-250 PV#2-250 PV# ml/ 8 GPH 1/2" NPT PV#1-500 PV#2-500 PV# ml/ 16 GPH 1/2" NPT PV# PV# PV# ml/ 32 GPH 1.0" NPT PV# PV# PV# ml/ 64 GPH 1.0" NPT PV# PV# PV# ml/ 160 GPH 2.0" NPT PV# PV# PV# ml/ 320 GPH 2.0" NPT PV# PV# PV# Note: PVC cylinders available with socket weld connections. Add suffix S to model # e.g. PV#3-100S For BSP threads, add suffix "B" to model # e.g. PV#3-100B PVC Construction Model Size Divisions Size Divisions A B (ml) (ml) (GPH) (GPH) (inches) (inches) PV# PV# PV# PV# PV# PV# PV# PV# PV#2/PV# PV#2/PV# PV#2/PV# PV#2/PV# PV#2/PV# PV#2/PV# PV#2/PV# PV#2/PV# Conversion Factors 1 ml = 1 cc 1000 ml = 1 liter ml/sec X 60 = ml/min 1 US gal/min X = liters/sec 1 US gal = liters Distributed By: (using return to tank) PRIMARY FLUID SYSTEMS INC. Registered Trade Mark of Primary Fluid Systems (using bottom connection with dust cover) Distribution Territories Available Call Toll Free Tel: (905) Fax: (905) E:Mail: primary@primaryfluid.com y e w

94 Note: ACCUDRAW PVC Calibration Instructions Before starting either of the calibration procedures below, ensure that the pump is primed and void of any trapped air. Using the USGPH scale: (scale is based on time, in one (1) minute volume discharge) 1. Fill the calibration to the top 0 mark on the USGPH scale. 2. Close isolation valve (#2) from supply tank, open isolation valve (#1) below cylinder and start the pump. 3. Use a stopwatch to measure the time of one (1) minute (60 seconds) and record the volume dispensed by the metering pump, using the draw down scale. 4. Adjust the pump volume control higher or lower to meet with your desired output. 5. Repeat above steps 1 through 4, until the desired output is met. 6. Divide the measured USGPH number by 60 to determine the USGPM volume, if required. If you wish to shorten the time of dispensing for calibration by one half (1/2) or one quarter (1/4), you must multiply the measured volume by the same number used to divide the time by. e.g. 10 USGPH in 1 minute equals 5 USGPH X 2 in 30 seconds or 2.5 USGPH X 4 in 15 seconds Using the ml scale: (scale is based on volume pumped, over any given time) 1. Fill the calibration cylinder to the top 0 mark on the ml scale. 2. Close isolation valve (#2) from supply tank, open isolation valve (#1) below cylinder and start the pump. 3. Use a stopwatch to measure the time it takes to pump down a given volume (ml) in 60 seconds. 4. Multiply the volume by 60 to determine the ml per hour volume, if required. 5. Adjust the pump volume control higher or lower to meet with your desired output. 6. Repeat above steps 1 through 5, until the desired output is met. If you wish to shorten the time of dispensing for calibration by one half (1/2) or one quarter (1/4), you must multiply the volume by the same number used to divide the time by to determine ml per minute or hour. e.g. 100 ml in 60 seconds equals 50 ml X 2 in 30 seconds or 25 ml X 4 in 15 seconds Typical Installations ("A" and "B") Conversion Factors 1 ml = 1 cc 1000 ml = 1 liter ml/sec X 60 = ml/min 1 US gal/min X = liters/sec 1 US gal = liters (using return to tank) (using bottom connection cylinder with dust cover) PRIMARY FLUID SYSTEMS INC. Call Toll Free Tel: (905) Fax: (905) primary@primaryfluid.com Registered Trade Mark of Primary Fluid Systems Inc.

95 Specifications Sizes: 1/2" 6" Models: PVC & CPVC: Socket, Threaded and Flanged (ANSI) PP & PVDF: IPS and Metric (DIN) Socket, Threaded, Butt and Flanged (ANSI) Bodies: PVC, CPVC, PP and PVDF Seats: PTFE backed with EPDM or FKM Seals: EPDM or FKM or AFLAS Standard Features (Sizes 1/2" 6") Pressure rated up to 230 psi (PVC, CPVC, PVDF) Double O-ring seals on stem for an added protection. Full bore, sizes 1/2" 2" Full vacuum rated, all sizes Blocks in two directions, upstream and downstream, leaving full pressure on the opposite end of the valve Integrally molded ISO mounting pad for both manual and actuated operations Integrally molded base pad to mount valves Securely or panel mounting PTFE seats with elastomeric backing cushions ensure bubble-tight shut-off and a low fixed torque, while at the same time compensating for wear True Union design for easier installation or repairs without expanding the pipe system Built-in spanner wrench on the handle for valve disassembly and assembly Two sets of end connectors (socket and threaded) included with all PVC and CPVC valves in sizes 1/2" 2" CPVC threaded end connectors on sizes 1/2" 1" come with stainless steel reinforcing rings Options Pneumatic and electric actuators & accessories Stem extensions 2" square operating nut or T nut Locking and/or spring return handles Limit switches Vented Ball 6 Type 21 Ball Valve Sizes 1/2" - 4" PVC/EPDM/FKM Models available with NSF-61 Certification Trademark of Asahi Glass Co., Ltd. Parts List (Sizes 1/2" 2") NO. D ESCRIPTION PCS. 1 ody 2 all PARTS * Used for flanged end **Used for CPVC body, threaded end, 1/2 1 MATERIAL CPVC, PP, B 1 PVC, PVDF B 1 PVC, CPVC, PP, PVDF 3 Carrier 1 PVC, CPVC, PP, PVDF 4 End Connector 2 PVC, CPVC, PP, PVDF 5 Union Nut 2 PVC, CPVC, PP, PVDF 6 Stem 1 PVC, CPVC, PP, PVDF 7 Seat 2 PTFE 8 O-Ring (A) 2 EPDM, FKM, Others 9 O-Ring (B) 1 EPDM, FKM, Others 10 O-Ring (C) 2 EPDM, FKM, Others 11 O-Ring (D) 1 EPDM, FKM, Others 12 O-Ring (E) 1 EPDM, FKM, Others 13 Stop Ring* 2 PVDF 14 Handle 1 ABS 4 a Ring* * Stainless Steel ASAHI/AMERICA Rev. C 03-05

96 Type 21 Ball Valves SOCKET END FLANGED END A H ød 1 11 L 4 THREADED END H 1 ød P.C.D. C ød l L t n- øh SPIGOT END t ød 2 l ød 1 1 ød 1 ød ød 1 L 4 4a 2-øS Depth S 2 3 ød ød 1 1 S 1 l L Dimensions (Sizes 1/2" 2") NOMINAL SIZE INCHES 1/2 5 FLANGED ANSI CLASS 150 SOCKET P VC, CPVC P P, PVDF (DIN) PP, PVDF (IPS) ASTM SCH 80 DIN mm d D C n h L t d1 d2 l L d1 d2 l L d1 l L / / / NOMINAL SIZE INCHES 1/2 5 THREADED SPIGOT (BUTT END) DIN 3442 PP,PVDF mm d1 l L D1 H H1 A d1 l t t L S1 S2 S3 1 1/ 2-14 NPT /4 20 3/ 4-14 NPT / 2 N PT / / / 2 N PT / / / 2 N PT / 2 N PT Green Street, P.O. Box 653, Malden, MA Tel: Fax: asahi@asahi-america.com Register at our interactive web site for on line ordering, product availability, order tracking, and many useful features: 7 PP PVDF

97 Type 21 Pressure vs. Temperature (PSI, WATER, NON-SHOCK) INCHES NOMINAL SIZE mm 30 F 70 F 1/ / Sample Specification All TYPE 21 Ball Valves, sizes 1/2 to 4, shall be of true union design with two-way blocking capability. All O-rings shall be EPDM or FKM with PTFE seats. PTFE seats shall have elastomeric backing cushion of the same material as the valve seals. Stem shall have double O-rings and be of blowout-proof design. The valve handle shall double as carrier removal and/or tightening tool. ISO mounting pad shall be integrally molded to valve body for actuation. PVC conforming to ASTM D1784 Cell Classification A, CPVC conforming to ASTM D1784 Cell Classification A, PP Conforming to ASTM D4101 Cell Classification PP0210B67272 and PVDF conforming to ASTM D3222 Cell Classification Type II. The ball valves, except PP, shall have a pressure rating of 230 psi for sizes 1/2 to 3 and 150 psi for 4 (150 psi for PP, all sizes) at 70 º F. Type 21 Ball Valves must carry a two-year guarantee, as manufactured by Asahi/America, Inc. Cv Values NOMINAL SIZE INCHES mm PVC 71 F 106 F 121 F 105 F 120 F 140 F 30 F 70 F Weight (POUNDS) CPVC 71 F 106 F 121 F 141 F 176 F 105 F 120 F 140 F 175 F 195 F Caution Never remove valve from pipeline under pressure. Always wear protective gloves and goggles. Watch out for trapped fluid in valve. It is safe to close valve before removing it from the pipeline. Caution Do not use ball valves where media has suspended particles. Use the following valves: Butterfly Valves PVDF disc is most abrasion resistant and make sure of chemical compatibility. Diaphragm Valves Elastomeric diaphragm is designed for handling suspended particles. Volatile fluids such as sodium hypochlorite (NaClO) and hydrogen peroxide (H 2 O 2 ) could be trapped and gasified within the valve. We can provide you with a Type 21 ball valve with a vented ball to relieve pressure build-up inside the valve. Troubleshooting What if the fluid still flows when valve is closed? 1. Carrier is not properly tightened. Tighten it. 2. PTFE seat is damaged or worn. Replace seat. 3. Foreign material is caught between ball and PTFE seat. Remove material and clean. 4. Ball is damaged or worn. Change ball. What if fluid leaks outside of valve? 1. Union nut not properly tightened. Retighten. 2. Carrier is not properly tightened. Thread it in firmly. 3. Carrier or face O-ring is damaged, worn, or missing. Replace O-ring. What if handle does not rotate smoothly? 1. Foreign material has formed on the ball or seat. Clean both. 2. Internal part(s) chemically attacked or swollen. Refer to Asahi/America Chemical Resistance Chart for compatibility. Replace part(s) as required. 3. Carrier over-tightened. Retighten properly. What if handle rotates too freely? 1. Stem is damaged. Replace stem. 2. Handle is not engaged with stem. Disassemble and reengage. Inspect. 3. Engaging part of stem and/or ball is damaged. Change stem and/or ball. 35 Green Street, P.O. Box 653, Malden, MA Tel: Fax: asahi@asahi-america.com Register at our interactive web site for on line ordering, product availability, order tracking, and many useful features: 9 PP -5 F 86 F 121 F 141 F 85 F 120 F 140 F 175 F Ball Valves -5 F 70 F PVDF 71 F 106 F 141 F 176 F 105 F 140 F 175 F 210 F NA NA NA CV 1/ / / / / NOMINAL SIZE INCHES mm SOCKET THREADED FLANGED 1/ / / / /

98 ASAHI AV VALVES Installation,Operation and Maintenance Manual Serial No. H V027 E 4 Ball Valve Type 21 User s Manual Contents (1) General operating instructions (2) General instructions for transportation, unpacking and storage (3) Name of parts (4) Comparison between working temperature and pressure (5) Installation procedure 4 (6) Operating procedure 9 (7) Method of Adjusting face pressure between ball and seat 9 (8) Disassembling method for parts replacement 10 (9) Mounting actuator, metal Ensert and base(panel) 11 (10) Inspection items 13 (11) Troubleshooting 13 (12) Handling of residual and waste materials 13 (13) Inquiries 14 ASAHI AV VALVES Ball Valve Type 21 0

99 ASAHI AV VALVES Installation,Operation and Maintenance Manual (1) General operating instructions Operate the valve within the pressure Vs temperature range. (The valve can be damaged by operating beyond the allowable range.) Select a valve material that is compatible with the media, refer to CHEMICAL RESISTANCE ON ASAHI AV VALVE. (Some chemicals may damage incompatible valve materials.) Do not use the valve to fluid containing slurry. (The valve will not operate properly.) Do not use the valve on condition that fluid has crystallized. (The valve will not operate properly.) Do not step on the valve or apply excessive weight on valve. (It can be damaged.) Do not exert excessive force in closing the valve. Make sure to consult a waste treatment dealer to dispose of the valves. (Poisonous gas is generated when the valve is burned improperly.) Allow sufficient space for maintenance and inspection. Keep the valve away from excessive heat or fire. (It can be deformed, or destroyed.) The valve is not designed to bear any kind of external load. Never stand on or place anything heavy on the valve at anytime. Certain liquid such as H2O2, NaClO, etc may be prone to vaporization which may cause irregular pressure increases, which may destroy the valve. (2) General instructions for transportation, unpacking and storage Keep the valve packed in the carton or box as delivered until installation. Keep the valve away from any coal tar, creosote (antiseptic for wood), termite insecticide, vermicides, and paint. (This could cause swelling damage the valve.) Do not impact or drop the valve. (It can be damaged.) Avoid scratching the valve with any sharp object. Ball Valve Type 21 1

100 ASAHI AV VALVES Installation,Operation and Maintenance Manual (3) Name of parts Nominal size 15-50mm (1/2-2 ) No. DESCRIPTION No. DESCRIPTION 1 Body 7 Seat 2 Ball 8 O-ring (A) 3 Carrier 9 O-ring (B) 4b End connector (Flanged end type) 10 O-ring (C) 4c End connector (Socket end type) 11 O-ring (D) 4d End connector (Threaded end type) 12 O-ring (E) 4e End connector(spigot type) 13 Stop ring 5 Union nut 14 Handle 6 Stem Nominal size mm (2 1/2-4 ) No. DESCRIPTION No. DESCRIPTION 1 Body 7 Seat 2 Ball 8 O-ring (A) 3 Carrier 9 O-ring (B) 4b End connector (Flanged end type) 10 Cushion 4c End connector (Socket end type) 11 O-ring (C) 4d End connector (Threaded end type) 12 O-ring (D) 4e End connector(spigot type) 13 Stop ring 5 Union nut 14 Handle 6 Stem 15 Screw Ball Valve Type 21 2

101 ASAHI AV VALVES (4) Comparison between working temperature and pressure Installation,Operation and Maintenance Manual Nominal size: 15mm-50mm (1/2-2 ) Nominal size: 65mm (2 1/2 ) Nominal size: 80mm, 100mm (3, 4 ) Caution Do not operate the valve beyond the range of working temperature and pressure. (The valve can be damaged.) Ball Valve Type 21 3

102 ASAHI AV VALVES Installation,Operation and Maintenance Manual (5) Installation procedure Flanged type (Material: PVC,C-PVC,PP,PVDF) Necessary items Torque wrench Spanner wrench AV gasket Bolt, Nut, Washer (For many flanges specification) (When a non-av gasket is used, a different tightening torque specification should be followed.) Procedure 1) When the union nut 5 flange assembly set was removed or loosen from body 1, O-ring (A) 8 should be installed into carrier and body groove. (In either horizontal or vertical installation, if necessary apply a small amount of lubricant to O-ring to hold in place.) Align union nut and end connector with the body. Insure end connector mates with body and O-ring. Make certain union nut threads onto body smoothly. Tighten union nuts on each side valve until hand tight. Then using a strap wrench tighten union nuts uniformly on each side approx 90 o -180 o turns, 1/4 to 1/2 turns. 2) Set the AV gasket between the flanges. 3) Insert washers and bolts from the pipe side, insert washers and nuts from the valve side, then temporarily tighten them by hand. Caution The parallelism and axial misalignment of the flange surface should be under the values shown in the following table to prevent damage the valve. (A failure to observe them can cause destruction due to stress application to the pipe) Nom. Size 15-32mm (1/2-1 1/4 ) 40-80mm (1 1/2-3 ) 100mm (4 ) Axial Misalignment Unit : mm (inch) Parallelism (a-b) 1.0mm (0.04 ) 0.5mm (0.02 ) 1.0mm (0.04 ) 0.8mm (0.03 ) 1.0mm (0.04 ) 1.0mm (0.04 ) (Axial misalignment) (Parallelism) 4) Tighten the bolts and nuts gradually with a torque wrench to the specified torque level in a diagonal manner. (Refer to fig.1.) Recommended torque value 15-20mm Nom. Size (1/2-3/4 ) 17.5 Torque value {179} [155] 25-40mm (1-1 1/2 ) 20.0 {204} [177] Unit: N-m{kgf-cm}[lb-inch] 50, 65 mm 80, 100 mm (2, 2 1/2 ) (3, 4 ) {230} {306} [230] [266] Fig. 1 Caution Avoid excessive tightening. (The valve can be damaged.) Ball Valve Type 21 4

103 ASAHI AV VALVES Threaded type (Material : PVC,C-PVC,PP,PVDF) Installation,Operation and Maintenance Manual Necessary items Sealing tape(a non-sealing tape can cause leakage.) Strap wrench(do not use Pipe wrench.) Spanner wrench Caution Make sure that the threaded connections are plastic x plastic. (Metallic thread can cause damage.) Procedure 1) Wind a sealing tape around the external thread of joint, leaving the end (about 3mm) free. 2) Loosen the union nut 5 with a strap wrench.. 3) Remove the union nut 5 and the end connector 4d. 4) Lead the union nut 5 through the pipe. 5) Tighten the external thread of the joint and the end connector 4d hardly with hand. 6) Using a spanner wrench, screw in the end connector 4d by turning carefully without damaging it. Caution Avoid excessive tightening. (The valve can be damaged.) 7) Make sure that the O-ring (A) 8 is mounted. 8) Set the end connector 4d and union nut 5 directly on the body without allowing the O-ring (A) 8 to come off. 9) Tighten union nuts 5 on each valve until hand tight. 10) Using a strap wrench tighten union nuts uniformly on each on each side approx turns, 1/4 to 1/2 turns. Caution Avoid excessive tightening. (The valve can be damaged.) Ball Valve Type 21 5

104 ASAHI AV VALVES Installation,Operation and Maintenance Manual Socket type (Material : PVC, C-PVC) Necessary items Adhesive for hard vinyl chloride pipes Strap wrench (Do not use the pipe wrench) Procedure Caution Do not install a socket type valve where the atmospheric temperature is 5 or lower. (The valve can be damaged.) 1) Loosen the union nut 5 with a strap wrench. 2) Remove the union nut 5 and end connector 4c. 3) Lead the union nut through the pipe. 4) Clean the hub part of the end connector 4c by wiping the waste cloth. 5) Apply adhesive evenly to the hub part of the end connector 4c and the pipe spigot. Caution Do not apply more adhesives than necessary. (The valve can be damaged due to solvent cracking.) Adhesive quantity (guideline) 15mm 20mm Nom. Size (1/2 ) (3/4 ) 25mm (1 ) 32mm (1 1/4 ) 40mm (1 1/2 ) 50mm (2 ) 65mm (2 1/2 ) 80mm (3 ) 100mm (4 ) Quantity(g) ) After applying adhesive, insert the pipe quickly to the end connector 4c and leave it alone for at least 60 seconds. 7) Wipe away overflowing adhesive. 8) Make sure that O-ring(A) 8 is mounted 9) Set the end connector 4c and union nut 5 directly on the body without allowing the O-ring (A) 8 to come off. 10) Tighten union nut 5 hardly with hand. 11) Using a strap wrench tighten union nuts uniformly on each side approx turns, 1/4 to 1/2 turns. Caution Avoid excessive tightening. (The valve can be damaged.) Ball Valve Type 21 6

105 ASAHI AV VALVES Socket type (Material : PP, PVDF ) Installation,Operation and Maintenance Manual Necessary items Strap wrench (Do not use the pipe wrench.) Sleeve welder or automatic welding machine User s manual for sleeve welder or automatic welding machine Procedure 1) Loosen the union nut with a strap wrench. 2) Remove the union nut 5 and the end connector. 3) Lead the union nut 5 through the pipe. 4) For the next step, refer to the user s manual for the sleeve welder or the automatic welding machine. 5) After welding, make sure that the O-ring (A) 8 is mounted. 6) Set the end connector 4c and the union nut 5 directly without allowing the O-ring (A) 8 to come off. 7) Tighten union nut 5 hardly with hand. 8) Using a strap wrench tighten union nuts uniformly on each side approx turns, 1/4 to 1/2 turns. Caution Avoid excessive tightening. (The valve can be damaged.) Spigot type (Material : PVDF ) Strap wrench (Do not use the pipe wrench.) Automatic welding machine User s manual for automatic welding machine Procedure Necessary items 1) Loosen the union nut with a strap wrench. 2) Remove the union nut 5 and the end connector. 3) Lead the union nut 5 through the pipe. 4) For the next step, refer to the user s manual for the sleeve welder or the automatic welding machine. 5) After welding, make sure that the O-ring (A) 8 is mounted. 6) Set the end connector 4e and the union nut 5 directly without allowing the O-ring (A) 8 to come off. 7) Tighten union nut 5 hardly with hand. 8) Using a strap wrench tighten union nuts uniformly on each side approx turns, 1/4 to 1/2 turns. Caution Avoid excessive tightening. (The valve can be damaged.) Ball Valve Type 21 7

106 ASAHI AV VALVES Installation,Operation and Maintenance Manual Caution {15mm-50mm(1/2-2 )} It is recommended to install the valve with the threaded carrier to the upstream side of the system. This allows for an increase safety factor and eliminating a threaded connection when used as a blocking valve. This also allows the down stream union nut and end connector to be removed safely under pressure. It increases the safety where there is no chance of thread leakage or accidentally removing the carrier. The designation of the up stream side (non threaded carrier is marked as shown) on the body. Nominal size 15mm - 50mm (1/2 2 ) Ball Valve Type 21 8

107 ASAHI AV VALVES Installation,Operation and Maintenance Manual (6) Operating Procedure Caution Avoid excessive tightening. (The valve can be damaged.) Turn the handle gently to open or close. (Turn the handle clockwise to close and counter clockwise to open.) Fully closed The position of the handle should be perpendicular to the pipe. Fully opened The position of the handle should be parallel to the pipe. Fully opened Fully closed (7) Method of Adjusting Face Pressure between Ball and Seat Necessary items Strap wrench Protective gloves Safety goggles Screwdriver (+) (only with nominal size 65~100mm) Procedure 1) Completely discharge fluid from pipes. 2) Turn the handle to full close. 3) Loosen the right union nut and the left one 5 with a strap wrench. 4) Remove the body part from piping system. Caution Wear protective gloves and safety goggles as some fluid remains in the valve. (You may be injured.) 5) Pull the handle off the body part. Caution As for nominal size mm (2 1/2-4 ), loosen the screw 15 properly with a screwdriver before pulling it off.. 6) Engage the upper convex part of the handle with the concave part of the union 3. Caution As for nominal size 15-50mm Only the union 3 on the right side when viewed from the trademark (AV mark) can be adjusted. As for nominal size mm adjust the unions on both sides. 7) Make an adjustment by turning the union clockwise (to tighten it) or counter clockwise (to loosen it). 8) Make sure that the handle can be operated smoothly. 9) Assemble the valve by following the above procedure in the reverse order, starting at 6) Ball Valve Type 21 9

108 ASAHI AV VALVES Installation,Operation and Maintenance Manual (8) Disassembling Method for Replacing Parts Necessary items Strap wrench Protective gloves Safety goggles Caution Wear protective gloves and safety goggles as some fluid remains in the valve. (You may be injured.) <Disassembly> Procedure 1) Completely discharge fluid from pipes. 2) Turn the handle to full close. 3) Loosen the right union nut and the left one 5 with a strap wrench. 4) Remove the body part from piping system. 5) Pull the handle off the body part. Caution As for nominal size mm (2 1/2-4 ), loosen the screw 15 properly with a screwdriver before pulling it off.. 6) Engage the upper convex part of the handle with the concave part of the union. Caution As for nominal size 15-50mm Only the union 3 on the right side when viewed from the trademark (AV mark) can be adjusted. As for nominal size mm, adjust the unions on both sides. 7) In the engaged state, turn the handle 14 counter clockwise to loosen it and remove the union 3. 8) Remove the seat 7 carefully by hand without damaging it. 9) Push out the ball 2 by hand. 10) Push out the stem 6 from the top flange side to the body side. <Assembly> Procedure Carry out the assembly work in the reverse procedure from item 10) Caution With regard to item 8), before installing seat 7 on the valve, check the seat for its face and back. Ball Valve Type 21 10

109 ASAHI AV VALVES Installation,Operation and Maintenance Manual (9) Mounting actuator, Ensat and base (panel) Attach actuator to the top flange Procedure 1) Remove the handle 14. Caution As for nominal 65mm-100mm, tighten the screw 15 properly before removing it. 2) Fix the stand 24 to actuator 23 with bolt (A). 3) Fix the stem 6 to the joint 25 with screw (B) 28. 4) Engage the joint 25 with actuator 23. 5) Fix the stand 24 to the top flange with bolt-nut (B) 27. 6) Make sure that the valve works smoothly, by operating actuator 23 by hand. Attach Inserted metal to the bottom stand. Procedure Refer to the user s manual for the Inserted metal (Commercially available.) Nominal 15-50mm(1/2-2 ) Bottom stand Bottom stand dimension Unit; mm Nom.Size S1 S2 S3 15mm (1/2 ) mm (3/4 ) mm (1 ) mm (1 1/4 ) mm (1 1/2 ) mm (2 ) mm (2 1/2 ) mm (3 ) mm (4 ) 65 <Nominal size 65~100mm> 11 8 Nominal mm (2 1/2-4 ) Bottom stand Ball Valve Type 21 11

110 ASAHI AV VALVES Fixation of bottom stand with panel Installation,Operation and Maintenance Manual Nominal size: 15mm-50mm (1/2-2 ) Before the fixation After the fixation Nominal size: 65mm-100mm (2 1/2-4 ) Before the fixation After the fixation Ball Valve Type 21 12

111 ASAHI AV VALVES Installation,Operation and Maintenance Manual (10) Inspection items Inspect the following items. (1) Existence of scratches, cracks, deformation, and discoloring. (2) Existence of leakage from the valve to the outside. (3) Existence of leakage when the valve is opened fully at right or left. (11) Troubleshooting Problem Cause Treatment Fluid leaks from the valve even when the valve is closed fully. Fluid leaks from the valve. The handle can not be turned smoothly. The handle fails to engage. The carrier is loosened. The seat is scratched or worn. Foreign matter is in the valve. The ball is scratched or worn. The union nut is loosened. The carrier is loosened. The O-ring is scratched or worn. Foreign matter is in the valve. Deformation. (By heat etc.) The stem is broken. The engagement between the stem and the ball is broken. Adjust the face pressure between the ball and the seat. (Refer to page 9) Replace the seat with a new one. Clean up. Replace the scratched ball with a new one. Tighten up the union nut. Adjust the face pressure between the ball and the seat. (Refer to page 9) Replace the O-ring with a new one. Clean up. Replace the parts. Replace the stem with a new one. Replace the stem and ball with new ones. (12) Handling of residual and waste materials Caution In discarding remaining or waste materials, be sure to ask waste service company. (Poisonous gas is generated.) Ball Valve Type 21 13

112 ASAHI AV VALVES Installation,Operation and Maintenance Manual (13) Inquiries ASAHI ORGANIC CHEMICALS INDUSTRY CO., LTD. Nobeoka Head Office : , Nakanose- Cho, Nobeoka City, Miyazaki- Pref., Japan. Tel : (81) Fax : (81) Tokyo Head Office : (Furukawachiyoda Bldg.) 15-9, Uchikanda 2- Chome, Chiyoda-Ku, Tokyo, Japan. Tel : (81) Fax : (81) Singapore Branch Office : 16 Raffles Quay, #40-03 Hong Leong Building, Singapore Tel : (65) Fax : (65) Europe Representative Office : Kaiser-Friedrich-Promenade 61 D Bad Homburg v. d. H. Germany. Tel : (49) Fax : (49) Shanghai Branch Office ASAHI /AMERICA Inc. : Room 1301-P Shanghai Kerry Center, 1515 Nanjing Xi Road, Shanghai China Tel : (21) Fax : (21) :35 Green Street P.O.Box 653, Malden, Massachusetts U.S.A. Tel : (1) Fax : (1) Distributor Ball Valve Type 21 14

113 ASAHI AV VALVES Installation,Operation and Maintenance Manual Ball Valves Type 21 ASAHI AV VALVES Information in this manual is subject to change without notice Ball Valve Type 21 15

114 Pump & Systems Accessories Pulsation Dampeners Pulsation dampeners operate on the principle that gas is compressible and fluid is not. The pulsation dampener consists of an air chamber containing compressed air, a fluid chamber connected to the pump's suction or discharge line, and a bladder or bellows which separates the air and fluid. Some models are flow-through design, with two ports so they can be mounted directly on the pump suction or discharge line. Other models are single port design, to be teed off of the pump suction or discharge line. Flow-through models may also be used in a tee if one port is capped. All models feature a Schrader (bicycle) valve and pressure gauge for charging the air chamber on-site. PVDF/Nordel pulsation dampeners are recommended for sodium hydroxide (caustic) applications. Viton pulsation dampeners are recommended for sodium hypochlorite applications. Sizing Pulsation Dampeners Multiply the pump's displacement per stroke (ml) times 26 to get minimum pulsation dampener volume (ml) to achieve 90% reduction in pulsation. Safety Note: We recommend using pressure relief valves with the pulsation dampeners. Fig. 1 8" (203) 1/4" Fig " (124.5) (mm) 1/2" NPT 2.85" (74.4) 8" (203) 1/4" 4.9" (124.5) (mm) 1/2" NPT Viton and HYPALON are registered trademarks of DuPont Dow Elastomers General Specifications Maximum pressure: 150 psig (polypro, PVDF and PTFE), 300 psig (SS) Temperature range: Nordel bladder: -60 F to 280 F (-51 C to 138 C) Viton bladder: 30 F to 350 F (-1 C to 177 C) HYPALON bladder: -20 F to 275 F (-29 C to 135 C) PTFE bellows: 40 F to 220 F (4 C to 104 C) Polypro housing : 32 F to 175 F (0 C to 79 C) PVC housing: 32 F to 140 F (0 C to 60 C) PVDF housing: 10 F to 250 F (-12 C to 121 C) PTFE housing: -20 F to 125 F (-29 C to 52 C) SS housing: 32 F to 200 F (0 C to 93 C) *Teflon bellows are smaller in volume Shipping Weight lbs (kg) Model Size Part No. 131 ml (8 cu. in.) Models SS housing: 3/8" FNPT, 1 port (not illustrated) PTFE bellows 3 (1.4) CTS1020 T III PVDF housing: 1/2" FNPT, 1 port (Fig. 1) PTFE bellows 1 (0.9) CTK1005 T 5 III ml (10 cu. in.) Models PVC housing: 1/2" FNPT,1 port (Fig. 1) Nordel bladder (EPDM) 1 (0.9) CTP1015 ND 5 III Viton bladder 1 (0.9) CTP1015 V 5 III HYPALON bladder 1 (0.9) CTP1015 H 5 III Polypro housing: 1/2" FNPT, 1 port (Fig. 1) Nordel bladder (EPDM) 1 (0.9) CTP1005 ND 5 III PVDF housing: 1/2" FNPT, 1 port (Fig. 1) Nordel bladder (EPDM) 1 (0.9) CTK1005 ND 5 III Viton bladder 1 (0.9) CTK1005 V 5 III ml (8 cu. in.) Models PVDF housing: 1/2" FNPT, 2 port (Fig. 2) PTFE bellows 1 (0.9) CTK1000 T III ml (10 cu. in.) Models PVC housing: 1/2" FNPT, 2 port (Fig. 2) Viton bladder 1 (0.9) CTP1010 V III HYPALON bladder 1 (0.9) CTP1010 H III Polypro housing: 1/2" FNPT, 2 port (Fig. 2) Nordel bladder (EPDM) 1 (0.9) CTP1000 ND III PVDF housing: 1/2" FNPT, 2 port (Fig. 2) Nordel bladder (EPDM) 1 (0.9) CTK1000 ND III Viton bladder 1 (0.9) CTK1000 V III product overview solenoid-driven metering pumps motor-driven metering pumps pump spare parts & accessories pump engineering specifications analytical instrumentation analytical sensors 4/21/ Accessories 151

115 PULSATION DAMPENERS 601 Columbia Ave, Bldg. D, Riverside, CA USA Tel: (800) or (951) Fax: (951) Website:

116 SENTRY PULSATION DAMPENERS BENEFITS & FEATURES Positive Displacement (PD) pumps create pulsation and hydraulic shock due to the reciprocating nature of their stroking action, potentially damaging the entire pumping system. Blacoh's SENTRY Pulsation Dampeners remove virtually all hydraulic shock, enhancing all-around performance and reliability of fluid handling equipment in industrial and chemical transfer applications. SENTRY BENEFITS: Produces a near steady fluid flow up to 99%* pulsation and vibration free. Protects pipes, valves, fittings, meters, and in-line instrumentation from destructive pulsations, vibrations, surges, cavitation, thermal expansion, & water hammer Creates steady and continuous flow when dosing, blending or proportioning additives Insures accuracy, longevity, and repeatability of in-line meters Enables uniform application of material in spraying and coating systems Reduces product agitation, foaming, splashing and degradation of product Provides liquid energy storage for emergency valve closure and equipment shutdown Reduces overall energy cost with continuous linear flow, rather than start/ stop turbulent flow Operates as a reservoir for make-up fluid SENTRY FEATURES: Sizes available for all positive displacement pumps with discharge sizes from 1/8" (3.18mm) to 6" (152.4mm) Simple, reliable design and quick installation Easy in-line maintenance Pressure ranges up to 4000 PSI (276 BAR) available from stock Temperature ranges from -60 F to +400 F (-51 C to +205 C) available from stock Custom models available up to 100 gallons (378L) and 25,000 PSI (1724 BAR) Bodies available in a full range of chemically resistant materials Bladders available for even the most corrosive application Let SENTRY Stand Guard Over Your System. Increase productivity, safety, reliability and efficiency. Decrease maintenance and operating costs. PROCESSES TRANSFER FILTERING PRINTING DOSING FILLING METERING SPRAYING COATING INJECTING MIXING INDUSTRIES SERVED Chemical Process Water Treatment Food & Beverage Pulp, Paper & Textile Paint & Coating Biotech/ Pharmaceutical Gas, Oil, & Petrochemical Consumer Products PRINCIPLES OF OPERATION SENTRY operates on the principle that volume is inversely proportional to pressure. Compressed air or gas is introduced into the air chamber of the SENTRY Pulsation Dampener to a specified pressure. The gas is entrapped by the elastomeric bladder, which prevents contact between the process fluid and compressed gas. (Without the bladder, the gas would dissolve into the fluid and cause product contamination). During pump discharge, fluid enters the wetted chamber of the SENTRY Pulsation Dampener, displacing the bladder, compressing the gas and absorbing the shock. During pump shift, liquid pressure decreases, the dampener gas expands, pushing fluid back into the process line, eliminating up to 99% of system shock and pulsation. AIR/GAS LIQUID TYPICAL INSTALLATIONS AODD, METERING, PERISTALTIC, & PISTON PUMPS PUMP STARTUP & SHUTDOWN QUICK CLOSING VALVES SENTRY SENTRY SENTRY SENTRY PUMP PUMP * Requires proper sizing.

117 SENTRY TECHNICAL SPECIFICATIONS SENTRY PLASTIC Pressure Rating*: Up to 150 PSI (10 BAR) Capacities: 4 cubic inches to 5 gallons ( L) Shell Materials: Polypropylene Conductive Polypropylene PVC and CPVC PVDF Conductive Acetal SENTRY METAL Pressure Rating*: Up to 4000 PSI (276 BAR) Capacities: 4 cubic inches to 100 gallons ( L) Shell Materials: Aluminum Carbon Steel 316L Stainless Steel Alloy 20 Hastelloy C Epoxy, PVDF and PTFE coated steel SENTRY SANITARY Pressure Rating*: Up to 1000 PSI (69 BAR) Capacities: 4 cubic inches to 10 gallons ( L) Shell Materials: 30 RA Polished 316L Stainless Steel Bead Blasted 316L Stainless Steel Temperature Range**: -20 F to +250 F (-29 C to C) Inlet Ports: Threaded: FNPT and BSP Flanged: ANSI and DIN Temperature Range**: -60 F to F (-51 C to +204 C) Inlet Ports: Threaded: FNPT and BSP Flanged: ANSI and DIN Temperature Range**: -20 F to +350 F (-28 C to +176 C) Inlet Ports: Tri-clamp type sanitary fitting SENTRY PTFE Pressure Rating*: Up to 100 PSI (6 BAR) Capacities 4 to 370 cubic inches (.066-6L) Shell Materials: Machined PTFE Temperature Range**: +40 F to F (+4 C to +104 C) Inlet Ports: Threaded: FNPT and BSP Flanged: ANSI and DIN Metric Flare Type SENTRY XP HIGH PRESSURE Pressure Rating*: Up to 4000 PSI (276 BAR) Capacities 8 to 24 cubic inches ( L) Shell Materials: 316L Stainless Steel Temperature Range**: -60 F to +225 F (-51 C to +107 C) Inlet Ports: Threaded: FNPT Flanged: ANSI SENTRY TEF-GUARD HP II Pressure Rating*: Capacities Shell Materials: Up to 2000 PSI (137 BAR) 12 cubic inches (.20L) 316L Stainless Steel Carbon Steel Alloy 20 Hastelloy C Temperature Range**: +40 F to F (+4 C to +104 C) Inlet Ports: Threaded: FNPT Flanged: ANSI BLADDER OPTIONS COMPOUND TEMPERATURE LIMITS APPLICATIONS Neoprene 0 F to +200 F (-18 C to +93 C) Good abrasion resistance and flex; use with moderate chemicals. Buna +10 F to +180 F (+12 C to +82 C) Good flex life; use with petroleum, solvents and oil-based fluids. EPDM -60 F to +280 F (-51 C to +137 C) Use in extreme cold; good chemical resistance with ketones, caustics. Hypalon -20 F to +275 F (-29 C to +135 C) Excellent abrasion resistance; good in aggressive acid applications. Viton -10 F to +350 F (-23 C to +176 C) Use in hot & aggressive fluids; good with aromatics, solvents, acids & oils. Aflas 0 F to +400 F (-18 C to +204 C) High temperature, petroleum based chemicals, strong acids and bases. FDA Silicone -20 F to +300 F (-29 C to +149 C) FDA-approved food grade material; for use in food and pharmaceutical processing. FDA Buna +10 F to +180 F (-12 C to +82 C) FDA-approved food grade. Similar characteristics of Silicone. FDA Fluorel -10 F to +350 F (-23 C to +176 C) Fluorel is a fluorelastomer comparable to Viton. PTFE +40 F to +220 F (+4 C to +104 C) Bellows design; excellent flex life; use with highly aggressive fluids. * Maximum PSI rated for ambient temperatures. ** Reflects entire temperature range for all available materials. Consult Blacoh on specific materials.

118 AIR CONTROL OPTIONS CHARGEABLE The chargeable model has a Schrader type charging valve that allows for a predetermined pressure charge to be applied and held in the dampener. No permanent source of compressed gas is required to be attached to the unit. The chargeable models are used primarily with metering, piston and peristaltic pumps for pulsation dampening. Chargeable models are also used for surge suppression to prevent water hammer from quick closing valves, for make-up fluid to prevent pump cycling and for suppression of pump start up or shut down pressure spikes. INLET STABILIZER The patented inlet stabilizer air control (U.S. Patent No. 6,089,837) consists of a compound pressure gauge, a pressure/vacuum tight ball valve and a venturi valve. When compressed air is passed through the venturi valve at high speed, a low pressure area is created which is used to evacuate the air from the stabilizer, creating a vacuum internally. Conversely, when the flow of air through the venturi valve is diverted into the stabilizer, a pressure charge is obtained. When pump inlet conditions are optimized, pump efficiency is maximized. AUTOMATIC An automatic poppet type valve located in the non-wetted section of the dampener allows for an increase in compressed air pressure to balance an increase in system liquid pressure. As liquid system pressure increases, the bladder is pushed further up into the dampener until it contacts the internal automatic valve. This contact opens the valve and allows an increase of compressed air to enter the dampener. When the air pressure inside the dampener equals the system liquid pressure, the dampener is in balance and pulsations are minimized. If a change in pressure occurs this process is repeated. Automatic units are designed for use on air operated diaphragm pumps in systems with a varying discharge pressure. ADJUSTABLE The adjustable model uses a self-relieving regulator to set dampener pressure. A compressed air line must be permanently attached to the regulator. The regulator allows for an easy, convenient method for readjusting the dampener pressure if the system fluid pressure changes. Adjustable units are designed for use on air operated diaphragm pumps in systems with a constant discharge pressure. APPLICATION STORIES APPLICATION: PULSATION DAMPENING PROBLEM: A major pulp & paper mill in the Northwest used AODD unloading pumps. The reciprocating action of these air-operated pumps created violent pulsations that caused both pipe stress and mounting fatigue. In fact, these pulsations often caused the pumps to be pulled from their cement foundations. This created significant downtime, costly foundation repair, environmental hazards, and a dangerous working environment. SOLUTION: A Blacoh SENTRY IV Pulsation Dampener was installed in the common discharge of the pumps to dampen these pulsations. RESULT: Pipe stress and mounting fatigue have been eliminated. Not only have the pumps not been ripped from their cement foundations, but the mill has experienced longer life from pump components such as diaphragms and ball valves. APPLICATION: WATER HAMMER PROBLEM: A major producer of water treatment chemicals accessed their local water supply through a 3 PVC pipe with quick-closing valves. When the desired quantity had been measured and the valve shut, a water hammer effect with pressure spikes that exceeded the PVC pipe s burst strength was created. The PVC repeatedly broke, causing the entire plant to be shut down for repair. In addition, since pipe failure occurred under a nearby highway, it also had to be closed. SOLUTION: A Blacoh SENTRY 10 gallon Surge Suppressor was installed on the pressure side of each quick closing valve to reduce water hammer pressure spikes. RESULT: The damaging water hammer pressure spikes are now absorbed, no pipes have ruptured, and the plant (and nearby highway) have had no downtime due to water hammer. APPLICATION: METERING PROBLEM: A 300 megawatt power plant required a chemical feed system to supply hydrazine to a boiler. The hydrazine acts as an oxygen scavenger, and must be delivered in a precise and consistent quantity. While metering pumps can deliver chemicals in precise amounts, their reciprocating action will not allow delivery in a smooth and consistent flow. SOLUTION: A Blacoh SENTRY III Pulsation Dampener was installed in the common discharge of two metering pumps to create smooth and consistent flow. RESULT: Hydrazine is now delivered to the boiler in a precise and consistent quantity. In addition, pipe vibration has been eliminated, gauge accuracy has been maximized, and pump component stress has been reduced. APPLICATION: SPRAYING/ COATING PROBLEM: A decontamination facility pumped acids and water through a series of 15 spray nozzles to rinse radiation from contaminated metals. However, the pulsating action of their reciprocating pumps caused uneven spray into the rinse tanks, and the metals were not rinsed completely. SOLUTION: A Blacoh SENTRY 1 Pulsation Dampener was installed at each pump discharge manifold to eliminate the surging flow of the pumps and ensure complete coverage and thorough cleaning. RESULT: The even flow ensures that the metal product is completely rinsed of radiation. Furthermore, both process time and the amount of acid required have been reduced, which increased productivity and profit.

119 UNDERSTANDING PULSATION AND WATER HAMMER CONTROL PULSATION DAMPENING Positive displacement pumps create pulsation and hydraulic shock purely by the reciprocating nature of the pump s stroking action. During the discharge stroke of a pump, fluid pressure takes the line of least resistance, displacing the bladder in the dampener, and compressing the trapped gas. As the pump begins its next cycle, fluid flow stops momentarily allowing the compressed gas to expand, forcing the bladder to push the accumulated fluid back into the discharge line. This fills the void created in the pipeline by the pump s cycle shift. Whether a piston, plunger, air diaphragm, peristaltic, gear, or diaphragm metering pump, a SENTRY Pulsation Dampener placed at the pump s discharge will produce a steady fluid flow up to 99% pulsation free; protecting the entire pumping system from the damaging effects of shock. SURGE SUPPRESSION & WATER HAMMER When fluid in motion is abruptly stopped, a hydraulic surge is created in the system. Hydraulic surge is often referred to as water hammer. The kinetic energy, released as pressure, can spike up to six times the system s operating pressure, destroying system instrumentation, pumps, pipes, fittings, and valves. Without a suppression device, the shock wave travels the length of the pipe back to the pump, then reverses again, oscillating back and forth until friction dissipates the pressure spike or a system component fails. There are several major culprits that produce water hammer; quick closing valves, back surge, pump start up and pump shut down. Quick closing valves can be defined as valves that close within one and one-half seconds. Quick closing valves have the potential of stopping large volumes of energized fluid, producing violent water hammer. The pump start up also stops fluid in motion. During pump start up, fluid in a pipe is static and must be accelerated. The pumped fluid is abruptly stopped when it contacts the static fluid in the pipe, again creating a shock wave. A SENTRY Surge INLET (SUCTION) STABILIZATION Without a sufficient supply of fluid a pump will not perform efficiently. Fluid starvation is caused by unbalanced hydraulics from friction, acceleration, and head. A reciprocating pump further complicates the issue by emitting high-frequency pressure waves created by the inlet valves opening and closing. In high inlet pressure situations, a pump s inlet valves create water hammer by their opening and closing action; increasing pipe and pump damage, and draining system efficiency. In suction lift and horizontal suction applications, the pumps inlet valve action actually decreases inlet fluid pressure. A starved or cavitating THERMAL EXPANSION Many fluids change volume due to temperature changes. As the temperature of a fluid rises, the fluid expands. In a closed or loop system a volumetric increase in fluid can create a rise in pressure beyond the limits of safety. The increase in pressure can result in ruptured pipes and fittings, Suppressor installed at the pump s discharge will provide the accumulation capacity to absorb the rapid fluid acceleration and prevent a pressure spike from occurring. As the surge enters the Suppressor, the gas inside is compressed, the fluid is accumulated and the shock wave is absorbed. When steady system flow rate is achieved, pressure and fluid are slowly released back into the system by the compressed gas. At pump shut-down, either planned or failure, fluid flow will momentarily continue away from the pump due to momentum. As the flow continues, a void, called column separation can occur at the pump s discharge. When fluid momentum is stopped due to pipe friction, the liquid will usually reverse toward the void area of the pump discharge. The reversing fluid will slam into the check valve usually located at the pump discharge and a water hammer pressure spike will occur. Depending upon the design of the piping system and the fluid involved, the voided area can actually become sub-atmospheric which can significantly increase the pressure spike. pump will be unable to produce specified flow rates due to the incomplete filling of cylinders and liquid chambers. In addition, cavitation will result in the premature failure of pump parts. A SENTRY Suction Stabilizer at the pump s inlet will act as an accumulator, reducing pressure fluctuations and aid in filling the pump head with fluid during each inlet stroke. In high suction lift applications it is also important not to lose the acceleration of the fluid created with each suction stroke of the pump. A Suction Stabilizer will momentarily maintain the flow of the accelerated fluid. The fluid flows into the stabilizer as the pump shifts, and then out as the inlet valve re-opens, maintaining even pressure and steady flow, minimizing cavitation. destroyed in-line instrumentation, burst pressure relief valves and contaminated surroundings. A SENTRY Thermal Expansion Chamber installed in the pipeline will accumulate the expanded fluid, eliminating a dangerous rise in pressure. ACCUMULATORS, AUXILIARY ENERGY, FLUID MAKE-UP & TRANSFER BARRIER Fluids flowing in a system can be accumulated during one part of the process cycle, and then released when needed during another part of the cycle. The release can be based upon the pressure of the system or by the opening/closing of a valve. The SENTRY Accumulator can be used to maintain process line pressure and store fluid for other uses, such as to back flush filters or to draw off sample fluid. Accumulators can be used as a Transfer Barrier where pressure on one side of a system needs to be transferred to another side without the mixing of the fluids. The accumulator is installed in-line with the two fluids entering at opposite ends, separated by the bladder. As the pressure of one fluid increases, it pushes the bladder against the other fluid, transferring the increase in pressure. Please call your local distributor: L / Columbia Ave, Bldg. D, Riverside, CA USA Tel: (800) or (951) Fax: (951) sales@blacoh.com Website:

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122 PARTS LISTING AND EXPLODED VIEW SENTRY MODEL RC-10X-V50 SENTRY MODEL #: MAXIMUM PRESSURE: CAPACITY: WETTED HOUSING: NONWETTED HOUSING: BLADDER: INLET: AIR CONTROL: RC-10X-V PSI/10 BAR 10 CUBIC INCH/.16 LITERS CPVC CPVC VITON 1/2" NPTF CHARGEABLE DESCRIPTION ITEM PART # QTY Component Material 1 10X Wetted Housing CPVC Bladder Viton 3 10X Nonwetted Housing CPVC Tee Steel Fill Valve Brass Gauge Plastic 11/18/2004 ITEM DIMENSIONAL DRAWING TOLERANCE ±.25" REV BLACOH FLUID CONTROL, INC RIVERSIDE, CALIFORNIA USA TEL: or Fax: sales@blacoh.com web site:

123 SENTRY INSTALLATION & OPERATION INSTRUCTIONS CHARGEABLE (C, CT & RC MODELS) S/N: MODEL #: DATE OF PURCHASE MATERIALS OF CONSTRUCTION: BODY BLADDER PUMP AREA & NUMBER SUPPLIER: COMPANY CONTACT PHONE FAX INSTALLATION NOTES READ BEFORE INSTALLATION To prevent pre-charge loss through the fill valve, always replace the cap after charging unit. If a system pressure test is to be performed, SENTRY must be charged with 80% of the system test pressure prior to test. This will avoid possible bladder damage. Blacoh recommends installing a pressure relief valve in all pump systems to ensure compliance with pressure limits on system equipment. Mount SENTRY as close to pump discharge, inlet and/or quick closing valve as possible, but within 10 pipe diameters. Temperature and pressure affect the strength and chemical resistance of plastic and rubber. Please consult factory for additional information. Remove all pressure from SENTRY unit AND pumping system before attempting maintenance. Do not exceed 150 PSI with plastic models; up to 300 PSI with CT units (all metal models excluding units with plastic nonwetted parts). Check pressure rating shown on serial tag. Always wear safety glasses when installing, charging or repairing SENTRY units. Do not operate a SENTRY that is leaking, damaged, corroded or unable to hold internal fluid, air or gas pressure. Pre-charge SENTRY with compressed air or nitrogen only. DO NOT USE OXYGEN DANGER OF STATIC SPARK: GROUNDING PRECAUTIONS MUST BE CONSIDERED WHEN USED IN FLAMMABLE OR EXPLOSIVE ENVIRONMENTS. INSTALLATION FOR PUMP DISCHARGE PULSATION READ BEFORE INSTALLATION Step 1 Installation Position Install the dampener in-line, as close to the pump discharge as possible to absorb the pulse at its source. Install ahead of any downstream equipment such as risers, valves, elbows, meters, or filters. Dampener installation should be no more than ten pipe diameters from pump discharge. If using a flexible connector from pump to system piping, dampener should be installed at the pump discharge manifold. The flexible connector should be attached to the dampener s tee and system piping (see Figure 1). Since pressure is equal in all directions, SENTRY can be installed in a vertical, horizontal, or upside-down position. Blacoh recommends a vertical installation for better draining of the unit. Limitations for horizontal and upside-down mounting include high specific gravity, high viscosity, settling of solid material, or possible air entrapment, which could result in shortened bladder life and/or poor dampening performance. Step 2 Air Line Connection Chargeable models do not require an air line connection. Units must be pre-charged with compressed air or Nitrogen, using a hand pump, tank/bottle or compressor. DO NOT USE OXYGEN. Charging hose kits are available part number Step 3 Charging and Start Up see PRE-CHARGE NOTES on next page. Prior to starting the pump, pre-charge SENTRY with compressed air or Nitrogen to approximately 80% of expected system pressure and replace fill valve cap. DO NOT USE OXYGEN. The gas pre-charge must always be lower than pump discharge pressure. Generally, pulsation is most effectively minimized when the gas charge is 80% of system pressure. Start the pump to generate system pressure. NOTE: Once system pressure is in contact with the bladder, the gas charge will be compressed to the system pressure and the dampener gauge will read the system pressure, not the initial charge pressure. Once working pressure is achieved, adjustment may be necessary. Gradually increase or decrease the gas charge in the dampener by bleeding or filling through the gas valve. Allow the system to respond to each adjustment (this may take a minute or two) before making further adjustments. BLACOH FLUID CONTROL, INC. 601 COLUMBIA AVE. BLDG. D, RIVERSIDE, CA USA TEL: or Fax: sales@blacoh.com web site:

124 INSTALLATION FOR PUMP INLET READ BEFORE INSTALLATION Step 1 Installation Position Install SENTRY as close to the pump inlet as possible. Install after any upstream equipment such as risers, valves, elbows, meters, or filters. If using a flexible connector from system piping to pump, SENTRY should be installed to the pump inlet manifold. The flexible connector should be attached to the SENTRY tee and system piping (see Figure 1). Step 2 Air Line Connection Chargeable models do not require an air line connection. Units must be pre-charged with compressed air or Nitrogen, using a hand pump, tank/bottle or compressor. DO NOT USE OXYGEN. Charging hose kits are available part number Step 3 Charging and Start Up see PRE-CHARGE NOTES. A. Suctions Lift/Accumulator: No pre-charge is required in a lift/accumulator installation. Start the pump to generate working pressure. As system pressure and vacuum is created, the acceleration head created with each suction stroke will compress the air trapped in the bladder. For better inlet stabilization, a SENTRY J Model is recommended. B. Positive Inlet Pressure: Pre-charge SENTRY with 50% of the static pressure realized at the pump inlet. Start the pump to generate working pressure. Minor pressure adjustments may be required. Allow the system to respond to each adjustment (this may take a minute or two) before making further adjustments. FIGURE 2 INSTALLATION FOR WATER HAMMER / SURGE Step 1 Installation Position Install SENTRY up stream from valve, as close as possible but no more than ten pipe diameters from the valve. (See Figure 2) Step 2 Air Line Connection Chargeable models do not require an air line connection. Units must be pre-charged with compressed air or Nitrogen, using a hand pump, tank/bottle or compressor. DO NOT USE OXYGEN. Charging hose kits are available part number Step 3 Charging and Start Up see PRE-CHARGE NOTES Prior to operating system, pre-charge SENTRY to 90% of system pressure and replace fill valve cap. Start the system. PRE-CHARGE NOTES READ BEFORE INSTALLATION READ BEFORE INSTALLATION Gas molecules will diffuse through elastomer membranes, the speed of which depends on elastomer material, temperature and pressure. As a rule of thumb, the pre-charge pressure should be checked every month. Checks must occur when no system pressure is present or inaccurate readings will be recorded. If temperature is above ambient and/or pressure is over 300 PSI, checks should be performed more frequently. Also, to prevent pre-charge loss through the fill valve, always replace the cap after charging. A proper gas charge is the key to dampener effectiveness and bladder life. IMPORTANT: AFTER MAINTENANCE OR RE-ASSEMBLY, TORQUE FASTENERS ACCORDING TO SPECIFICATION ON THE UNIT TAG. Standard Product Warranty: Blacoh Fluid Control warrants its products to be free of defective material and workmanship under normal use and service for two years from date of shipment. The remedy for any product defect covered under this warranty shall be limited to the replacement or repair of the defective part or parts and Blacoh will not be responsible for damages or injury caused to other products, machinery, buildings, property or person. This warranty shall be null and void if the product has been altered, misapplied, misused, or neglected of maintenance. Damage or loss resulting from over-pressurization of a product, whether from gas or fluid does not constitute a defect covered under this warranty nor will Blacoh be responsible in any way for any such damage or loss. Because Blacoh cannot anticipate or control the many different conditions under which its products may be used, Blacoh does not guarantee the applicability or suitability of its products for any particular use or purpose. Each user of Blacoh products should conduct its own tests to determine the suitability of each product for its intended uses or purposes. Blacoh products are sold with this limited warranty and each buyer assumes all responsibility for loss or damage, including consequential damage, arising from the handling and use of Blacoh products whether used in accordance with Blacoh s directions or otherwise. Statements concerning the possible use of Blacoh products are not intended as recommendations for any specific use of such products. This Standard Product Warranty shall be governed by and construed in accordance with the laws of the State of California. BLACOH FLUID CONTROL, INC. 601 COLUMBIA AVE. BLDG. D, RIVERSIDE, CA USA TEL: or Fax: sales@blacoh.com web site: L-180 REV 11/09/04

125 HAYWARD SYSTEMS FlowControl Y Strainers 1/2" to 4" - PVC and Corzan CPVC Economical Protection Hayward Y Strainers protect piping system components from damage caused by dirt or debris in the process media. They cost less than other types of strainers and are lightweight and very compact. Because they can often be supported by the pipeline alone, they work in applications where other strainers cannot. Features Rated to 150 PSI Viton Seals Standard 1/32" perf screen All-Plastic Construction Easy Screen Access Can Be Used in Horizontal or Vertical Position Corzan is a trademark of BF Goodrich Company Viton is a trademark of DuPont Dow Elastomers Options Stainless Steel Strainer Screens Rugged Plastic Screens Hayward Y Strainers are supplied with a 1/32" perforated plastic screen. This screen is ultrasonically welded, not glued, for superior strength. Screens fabricated from type 316 stainless steel are also available in openings from 1/2" down to super fine 325 mesh. All screens have an open area at least twice that of the equivalent pipe size cross-sectional area to minimize pressure drop. Easy Clean Out All sizes of Hayward Y Strainers feature a heavy-duty hex cap that permits quick and easy removal of the strainer screen when cleanout becomes necessary. Adaptable Design Hayward Y Strainers will work equally well in the horizontal or vertical position, simplifying piping system layout. All Plastic Construction Hayward Plastic Y Strainers will never rust or corrode and they don t require painting or coating to survive corrosive environmental conditions.

126 Technical Information FLOW 4 B E A F Parts List Y Strainer 3 2 J G D H Clearance For Removal 1 C 1. Cap 2. O-Ring Seal 3. Screen 4. Body Dimensions - Inches / Millimeters Weight (lb / kg) Size A B C D E F G H J Skt / Thd Flg 1/2" 3.38 / / / / 38 N/A 0.56 / / / / /.11 N/A 3/4" 4.18 / / / / 51 N/A 0.81 / / / / /.29 N/A 1" 5.19 / / / / 55 N/A 1.00 / / / / /.40 N/A 1-1/4" 6.63 / / / / 75 N/A 1.25 / / / / /.80 N/A 1-1/2" 6.63 / / / / 75 N/A 1.56 / / / / /.74 N/A 2" 7.63 / / / / / / / / / / / /2" / / / / 133 N/A 2.90 / / / / / 3.5 N/A 3" / / / / / / / / / / / 5.7 4" / / / / / / / / / / / 8.0 Cv Factors* Size Factor Size Factor 1/2" 4.0 2" 28 3/4" /2" 40 1" 9.0 3" /4" 12 4" /2" 28 * With 1/32" plastic screen Operating Temperature/Pressure WORKING PRESSURE (PSI) TEMPERATURE C PVC Pressure Drop Calculations CPVC The pressure drop across the strainer, for water or fluids with a similar viscosity, can be calculated using the formula at the right: TEMPERATURE F WORKING PRESSURE (kpa) P = [ Q Cv] 2 Where P = Pressure Drop Q = Flow in GPM Cv = Flow Coefficient Selection Chart The pressure loss across a valve or filter can be calculated using the system's flow rate and the Cv factor for that valve or filter. For example, a 1" strainer with a Cv factor of 8 will have a 4 psi pressure loss in a system with a 16 gpm flow rate (16 8) 2 = 4 Size Material End Connection Seal Rating 1/2 to 4" PVC, CPVC Thd, Skt, Flg* Viton F * 1/2" to 1-1/2" not available with flanged connections Strainer Screen Selection Y Strainers are furnished with a 1/32" or 1/16" perf plastic screen. Stainless steel strainer screens are available in these perfs: 1/32", 3/64", 1/16", 5/64", 7/64", 1/8", 5/32", 3/16", 1/4", 3/8", 1/2"; and in mesh sizes: 20, 40, 60, 80, 100, 200, 325 HAYWARD Hayward Industrial Products, Inc. One Hayward Industrial Drive, Clemmons, NC Tel: (1-888-HAYINDL) Fax: industrial@haywardnet.com Web Site: Hayward Industrial Products Canada Inc Plymouth Drive, Oakville, Ontario L6H 5R4 Tel: Fax: Hayward Industrial Products (UK) Ltd. Unit 2, Crowngate, Wyncolls Road, Colchester, Essex C04 4HT Tel: Fax: MC-8-YST Rev. 2 Printed in U.S.A.

127 HAYWARD INDUSTRIAL PRODUCTS INSTALLATION OPERATION & MAINTENANCE OF Y-STRAINER PLEASE READ THE FOLLOWING INFORMATION PRIOR TO INSTALLING AND USING HAYWARD VALVES, STRAINERS, FILTERS, AND OTHER ASSOCIATED PRODUCTS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS INJURY. 1. Hayward guarantees its products against defective material and workmanship only. Hayward assumes no responsibility for damage or injuries resulting from improper installation, misapplication, or abuse of any product. 2. Hayward assumes no responsibility for damage or injury resulting from chemical incompatibility between its products and the process fluids to which they are subjected. Compatibility charts provided in Hayward literature are based on ambient temperatures of 70F and are for reference only. Customer should always test to determine application suitability. 3. Consult Hayward literature to determine operating pressure and temperature limitations before installing any Hayward product. Note that the maximum recommended fluid velocity through any Hayward product is eight feet per second. Higher flow rates can result in possible damage due to the water hammer effect. Also note that maximum operating pressure is dependent upon material selection as well as operating temperature. 4. Hayward products are designed primarily for use with non-compressible liquids. They should NEVER be used or tested with compressible fluids such as compressed air or nitrogen. 5. Systems should always be depressurized and drained prior to installing or maintaining Hayward products. 6. Temperature effect on piping systems should always be considered when the systems are initially designed. Piping systems must be designed and supported to prevent excess mechanical loading on Hayward equipment due to system misalignment, weight, shock, vibration, and the effects of thermal expansion and contraction. 7. Because PVC and CPVC plastic products become brittle below 40F, Hayward recommends caution in their installation and use below this temperature. 8. Published operating torque requirements are based upon testing of new valves using clean water at 70F. Valve torque is affected by many factors including fluid chemistry, viscosity, flow rate, and temperature. These should be considered when sizing electric or pneumatic actuators. 9. Due to differential thermal expansion rates between metal and plastic, transmittal of pipe vibration, and pipe loading forces DIRECT INSTALLATION OF METAL PIPE INTO PLASTIC CONNECTIONS IS NOT RECOMMENDED. Wherever installation of plastic valves into metal piping systems is necessary, it is recommended that at least 10 pipe diameter in length of plastic pipe be installed upstream and downstream of the plastic valve to compensate for the factors mentioned above. SOCKET CONNECTION: Socket end connections are manufactured to ASTM D Solvent cementing of socket end connections to pipe should be performed per ASTM specifications D Cut pipe square. Chamfer and deburr pipe. Surfaces must be cleaned and free of dirt, moisture, oil and other foreign material. Apply primer to inside socket surface of the strainer. Never allow primer or cement to contact sealing surfaces or the screen, as leaking may result. Use a scrubbing motion. Repeat applications may be necessary to soften the surface of the socket. Next, liberally apply primer to the male end of the pipe to the length of the socket depth. Again apply to the socket, without delay apply cement to the pipe while the surface is still wet with primer. Next apply cement lightly, but uniformly to the inside of the socket. Apply a second coat of cement to the pipe, and assemble the strainer to the pipe, rotating the strainer 1/4 turn in one direction as it is slipped to full depth on to the pipe. The strainer should be held in position for approx. 30 seconds to allow the connection to set. After assembly wipe off excess cement. Full set time is a minimum of 30 minutes at 60 to 100 F. Full cure time should be based on the chart below. JOINT CURE SCHEDULE: The cure schedules are suggested as guides. They are based on laboratory test data, and should not be taken to be the recommendations of all cement manufacturers. Individual manufacturer s recommendations for their particular cement should be followed. Temperature Test Pressures for Pipe Test Pressures for Pipe Test Pressures for Pipe Test Pressures for Pipe Range During Sizes 1/2 to 1-1/4 In. Sizes 1-1/2 to 3 In. Sizes 4 to 5 In. Sizes 6 to 8 In. Cure Period(B) Up to Above 180 to Up to Above 180 to Up to Above 180 to Up to Above 180 to ºF(ºC) 180 PSI 370 PSI ( PSI 315 PSI 1240) 180 PSI 315 PSI ( PSI 315 PSI (1240 (1240 kpa) to 2550 kpa) (1240 kpa) to 2170 kpa) (1240 kpa) to 2170 kpa) (1240 kpa) to 2170 kpa) 60 to 100 (15 to 40) 1 h 6 h 2 h 12 h 6 h 18 h 8 h 24 h 40 to 60 ( 5 to 15) 2 h 12 h 4 h 24 h 12 h 36 h 16 h 48 h 20 to 40 ( -7 to 5) 6 h 36 h 12 h 72 h 36 h A 4 days A 3 days A 9 days A 10 to 20) (-15 to 7) 8 h 48 h 16 h 96 h 72 h A 8 days A 4 days A 12 days A Colder than 10 (-15) Extreme care should be exercised on all joints made where pipe, fittings or cement is below 10ºF. A: It is important to note that at temperatures colder than 20ºF on sizes that exceed 3 in., test results indicate that many variables exist in the actual cure rate of the joint. The data expressed in these categories represent only estimated averages. In some cases, cure will be achieved in less time, but isolated test results indicate that even longer periods of cure may be required. B: These cure schedules are based on laboratory test data obtained on Net Fit Joints (NET FIT=in a dry fit the pipe bottoms snugly in the fitting socket without meeting interference). THREADED CONNECTION: Threaded end connections are manufactured to ASTM specifications D F and ANSI B2.1. Wrap threads of pipe with Teflon tape of 3 to 3-1/2 mil thickness. The tape should be wrapped in a clockwise direction starting at the first or second full thread. Overlap each wrap by, 1/2 the width of the tape. The wrap should be applied with sufficient tension to allow the threads of a single wrapped area to show through without cutting the tape. The wrap should continue for the full effective length of the thread. Pipe sizes 2 and greater will not benefit with more than a second wrap, due to the greater thread depth. To provide a leak proof joint, the pipe should be threaded into the end connection hand tight. Using a strap wrench only. (Never use a stillson type wrench) tighten the joint an additional 1/2 to 1-1/2 turns past hand tight. Tightening beyond this point may induce excessive stress that could cause failure.

128 FLANGED CONNECTION: Flange bolts should be tight enough to slightly compress the gasket and make a good seal, without distorting or putting excessive stress on the flanges. Suitable washers should be used between the bolt head and flange and the nut and flange. Bolts should be tightened in alternating sequence. RECOMMENDED FLANGE BOLT TORQUE. USE WELL LUBRICATED METAL BOLTS AND NUTS. USE SOFT RUBBER GASKETS. FLANGE BOLT TORQUE FLANGE BOLT TORQUE SIZE DIA. FT. LBS. SIZE DIA. FT. LBS. 1/2 1/ / /4 1./ /2 5/ / / /4 1/ / /2 1/ / INSTALLATION: It is recommended that these strainers be installed no closer than 10 pipe diameters from a pump. At least 5 pipe diameters should be between these strainers and an elbow. As in all plastic piping the maximum fluid velocity is 8 feet per second. This velocity minimizes the effects of valve closure and pump start up or shut down. SCREEN CLEANING: EXTREME CAUTION MUST BE TAKEN WHEN WORKING ON THIS STRAINER. THE PIPING SYSTEM MUST BE DEPRESSURIZED AND DRAINED. PROPER CARE MUST BE TAKEN. CONSULT M.S.D.S. (MATERIAL SAFETY DATA SHEETS) INFORMATION REGARDING YOUR SPECIFIC APPLICATION. When the pressure drop across the strainer is in excess of 5 PSI the screen requires cleaning. To clean the screen remove the screen cap nut from the strainer by turning counter clockwise. The collected debris should be removed with the screen. Clean the screen. DO NOT POUND OR DEFORM THE SCREEN. Insert the screen back into the strainer with the flange, if one is on the screen into the body first. Install the o-ring in the body groove. Use a non-petroleum base lubricant to lubricate the o-ring and thread, and re-assemble the cap to the strainer. STRAINER BODY O-RING CPVC STRAINER SCREEN STRAINER CAP PVC YSIS REV B 9/7/99 ECR 819R

129 Griffco Valve Inc N. Bailey Ave., Ste 1B Amherst, NY Phone: Fax: T-SERIES BACK PRESSURE VALVES Features: High Reliability / Low Cost No Bolts on Plastic Models Compact Size for OEM Applications Adjustable PSI Optional 350 PSI Rated Valve Anti-Siphon Function Robust, Machined Construction Vulcanised PTFE/EPDM Diaphragm Wide Range of Materials Griffco diaphragm back pressure valves are designed to enhance the performance of chemical feed systems by applying a continuous back pressure to the chemical feed pump, while also acting as an anti-syphon valve. Robust construction ensures reliability in the rigorous service of municipal and industrial applications. Wetted materials include: PVC, CPVC, PP, PVDF, PTFE, 316 SS, A 20 and Hast. C. Available sizes: 1/4-1/2. Operation: Griffco diaphragm back pressure valves apply positive discharge pressure to a metering pump system to prevent siphoning and eliminate varying dosage rates caused by fluctuating downstream pressure. The diaphragm is held against the valve seat by an internal spring. When the preset pressure is exceeded, the diaphragm is forced up and chemical flows through the valve to the injection point. The valves are preset for 50 psi, however they are field adjustable from psi via the adjustment screw. Installation should be as close to the injection point as possible to prevent chemical line drainage, and it is most important that all chemical system equipment such as pulsation dampeners and pressure gauges are between the pump and back pressure valve. TYPICAL INSTALLATION GRIFFCO BACK PRESSURE / ANTI-SYPHON VALVE C/W OPTIONAL PRIMING VALVE PRESSURE GAUGE PULSATION DAMPENER INJECTION VALVE CHEMICAL CONTAINER GRIFFCO CALIBRATION CYLINDER GRIFFCO PRESSURE RELIEF VALVE SHUT OFF VALVE DRAIN VALVE Y-STRAINER ISOLATING BALL VALVES OPTIONAL PRESSURE RELIEF PIPING CHEMICAL FEED PUMP CALL GRIFFCO Bulletin # BPV

130 Technical Data: Sizes: Model BPT 1/4, 3/8, 1/2 Connections: Pressure Adjustment Flow 150 psi NPT and Socket psi, psi, psi, psi Shipping Weight: lbs Size Pulsating Continuous Plastic Metal / Plastic Top Metal / Metal Top 1/4 3/8 1/2 100 USgph 200 USgph 300 USgph 5 USgpm 10 USgpm 15 USgpm Max Temperature: ( F) PVC: 140 ; CPVC: 190 ; PTFE & PVDF: 280 ; Metal: 300, (Short Term 390 ) Max Operating 70 F: (psi) Materials of Construction: Diaphragm Valve Top Valve Body Performance Curves: Plastic/Noryl: 375 psi, Metal /Metal: 2000 psi PTFE / EPDM, Optional: Viton & PTFE / Viton Standard: Noryl (Threaded to Plastic Valves, Bolted to Metal Valves) Optional: 316 SS, (Alloy tops fit alloy valves ONLY) PVC, CPVC, PP, PTFE, PVDF, 316 SS, A 20, Hast. C, Others on Request Dimensions: A D C Product Codes For Ordering: BPT = Size 2 = Material 3 = Options 025-1/4 P - PVC V - Viton Diaphragm 038-3/8 CP - CPVC S - Socket Connections 050-1/2 PP - Polypro OSS - Optional 316 SS Top T - PTFE MSS psi; 316 SS Top K - PVDF AR - Optional Air Release Port S SS A - Alloy 20 C - Hastalloy C B D A B C 1/4 Plastic /4 Metal /8 Plastic /8 Metal /2 Plastic /2 Metal Note: Options OS, OSS, MS, & MSS are only for use on 316SS, A20, & Hast C Valves. For more detailed information visit us at

131 Griffco Valve Inc North Bailey Ave, Suite 1B Amherst, NY Phone: or GRIFFCO Fax: or Instruction Manual Back Pressure Valves Pressure Relief Valves Call GRIFFCO Website: INS

132 INTRODUCTION GRIFFCO diaphragm back pressure valves are used to enhance the performance of chemical feed pumps and systems by providing a constant discharge head pressure. These valves also function as an anti-siphon valve. The diaphragm is held against the seat by the internal spring. Back pressure is adjustable from psi via the adjustment screw. When the inlet pressure exceeds the preset pressure the diaphragm lifts off the seat and the chemical flows to the injection point. After each discharge stroke of the pump, as the pressure drops, the diaphragm reseats itself. GRIFFCO diaphragm pressure relief valves are designed to protect chemical feed pumps and systems from overpressure caused by defective equipment or blockages in the chemical line. The 3 port design allows chemical to flow through the valve via an internal chamber. When the pressure in the chemical line exceeds the preset pressure of the valve the diaphragm lifts off the seat and the chemical then flows out the bottom port back to the chemical tank. Relief pressure is adjustable form psi via the adjustment screw in the top of the valve. INSTALLATION Back Pressure Valve: Generally, the back pressure valve can be installed anywhere in the discharge line, provided there is some downstream pressure at the dosage point. If there is no downstream pressure the back pressure valve should be installed at the dosage point to prevent siphoning and drainage of the chemical line. All GRIFFCO valves are factory set at 50 psi, unless otherwise specified. Field adjustment is possible with the adjustment screw. Back pressure valve performance will be enhanced with the installation of a pulsation dampener to smooth out the discharge / suction cycles of the pump. Thus, the diaphragm is free to float inside the valve chamber, minimizing the wear on the stress points of the diaphragm. For many low pressure applications dampeners without diaphragms are acceptable. These pulsation dampeners should be sized at times the dosage volume of the pump head. For some applications diaphragm type dampeners are required. Generally speaking 5 to 10% dampening is sufficient. Consult with your pump manufacturer to get his recommendations. Pressure Relief Valve: Installation should be made as close to the chemical pump discharge valve as possible, without any equipment, especially shut-off valves, between the valve and the pump. Direction of flow must be across the valve, however the side of entry is not important. All GRIFFCO valves are factory set at 50psi, however field adjustment is possible with the adjustment screw. The optimum installation for the relief valve is to vent the relief port back to the chemical tank, or directly to a containment area. However if this is not possible, the relief port can be piped back into the suction side of the pump. This will apply the suction head to the relief port. To compensate, divide the NPSH by 4 and add this pressure to the relief valve setting.

133 TYPICAL INSTALLATION GRIFFCO BACK PRESSURE / ANTI-SIPHON VALVE C/W OPTIONAL PRIMING VALVE PRESSURE GAUGE PULSATION DAMPENER INJECTION VALVE CHEMICAL CONTAINER GRIFFCO CALIBRATION CYLINDER GRIFFCO PRESSURE RELIEF VALVE SHUT OFF VALVE DRAIN VALVE Y-STRAINER ISOLATING BALL VALVES OPTIONAL PRESSURE RELIEF PIPING CHEMICAL FEED PUMP DIMENSIONS: MAINTENANCE: The pressure relief and back pressure valves were designed with minimizing the amount of maintenance required to keep the valves in operation. However, periodic replacement of the diaphragm is required. To facilitate inspection and replacement, the valve layout is such that removal of the diaphragm can be done without taking the valve out of the chemical line. Caution: Ensure the system is not under pressure and that the chemical lines are flushed with water before disassembly. Unscrew the pressure adjustment screw to remove the pressure from the diaphragm. Remove the 4 cap nuts and lift off the valve top. (On T-Series valves unscrew the valve top) After the diaphragm and the valve seat have been inspected and replaced if necessary check the adjustment spring. Make sure there is no rust or corrosion. Replaced the spring and the spring bumper into the valve top and slide the top back over the four bolts. (On T-Series valves thread the valve top to the valve body) Snug down the four cap nuts. (On T-Series Snug hand tight then tighten ¼ turn) Screw in the tension adjuster to approximately the same position as it was prior to disassembly. If an exact pressure setting is required or a different pressure is desired a pressure gauge should be used to verify the setting. Pressure can be increased by turning the pressure adjustment screw clockwise. D B O nly o n 3 Port Pressure Relief Valve D A B C 1/ / /2 T-Series / / / NOTE: Dimensions are general. See dimension sheets for exact sizes of various material valves. C A

134 PARTS LIST ITEM DESCRIPTION PART # 1 Bolt - 1/2-1" Plastic Valves ¼ - 20 X 2 ¾ Bolt - 1 1/2-2 Metal Valves 5/16 18 X 1 ½ Bolt - 1 1/2-2 Plastic Valves 5/16 18 X 5 Bolt - 1/4" Plastic Valves 10/32 x 1 ¾ Bolt - 1/4" Metal Valves 10/32 X ¾ Bolt - 1/2-1" Metal Valves ¼ - 20 x 1 ¼ /32 Cap hex nut 1/4-20 Cap hex nut 5/16-18 Cap hex nut 10/32 Flat washer 1/4 Flat washer 5/16 Flat washer 4 1/4" 1/2 T-Series Alloy Valve Top, Bolted Noryl, Grey 1/4" 1/2 T-Series Alloy Valve Top, Bolted PVC, Orange 1/4" 1/2 T-Series Alloy Valve Top, Bolted PVC, Yellow 1/4" 1/2 T-Series Alloy Valve Top, Bolted PVC, Green 1/4" 1/2 T-Series Valve Top, Threaded Noryl, Grey 1/4" 1/2" T-Series Valve Top, Threaded PVC, Orange 1/4" 1/2" T-Series Valve Top, Threaded PVC, Yellow 1/4" 1/2" T-Series Valve Top, Threaded PVC, Green 1/2" External Adjustment Valve Top PVC (Tiberian) 1/4" 1/2 T-Series Alloy Valve Top Coated Steel 1/4" 1/2 T-Series Alloy Valve Top 316 SS 1/2" - 1" Valve Top PVC. Grey 1/2" - 1" Valve Top PVC, Orange 1/2" - 1" Valve Top PVC, Yellow 1/2" - 1" Valve Top PVC, Green 1/2" - 1" Valve Top CPVC 1/2" - 1" Valve Top - Steel 1/2" - 1" Valve Top SS 1 1/2-2 Valve Top; 5 ½ Valves, PVC 1 1/2-2 Valve Top; 5 ½ Valves. Coated Steel 1 1/2-2 Valve Top; 5 ½ Valves. 316 SS 1 1/2 Valve Top; 4 ½ Valves, PVC 1 1/2 Valve Top; 4 ½ Valves. Coated Steel 1 1/2 Valve Top; 4 ½ Valves. 316 SS 2 Valve Top; 5 Valves, PVC 2 Valve Top; 5 Valves. Coated Steel 2 Valve Top; 5 Valves. 316 SS Pressure Spring - 1/4" 1/2 T-Series Valve; psi Pressure Spring - 1/4" 1/2 T-Series Valve; 0 50 psi Pressure Spring - 1/4" 1/2 T-Series Valve; psi Pressure Spring - 1/2" - 1" Valve; psi Pressure Spring - 1/2" - 1" Valve; 0 50 psi Pressure Spring - 1/2" - 1" Valve; psi Pressure Spring - 1/2" - 1" Valve; psi, 316 SS Pressure Spring - 1 1/2-2 Valve Support Disc - 1/4" 1/2 T-Series Valve, PP Support Disc - 1/4" 1/2 T-Series Valve, 316 SS Support Disc 1/2-1" Valve, PP Support Disc 1/2-1" Valve, 316 SS Support Disc 1 1/2-2 Valve, PP Support Disc 1 1/2-2 Valve, 316 SS Diaphragm - 1/4" 1 /2 T-Series Valve - PTFE / EPDM Diaphragm - 1/4" 1 /2 T-Series Valve - Viton Diaphragm - 1/4" 1 /2 T-Series Valve - PTFE / Viton (High Temp) Diaphragm - 1/2" - 1" Valve - PTFE / EPDM Diaphragm - 1/2-1 Valve Viton Diaphragm - 1/2" - 1" Valve - PTFE / Viton (High Temperature) Diaphragm - 1 1/2 PTFE / EPDM 3.25 Diameter Diaphragm - 1 1/2 - Viton 3.25 Diameter Diaphragm 2 Valve 3.5 Diameter Diaphragm 2 Valve Viton 3.5 Diameter 9 Adjustment Screw - 1/4-1 Valve PVC Adjustment Screw - 1/4-1 Valve PVC, Slotted Adjustment Screw - 1/4-1 Valve Coated Steel Adjustment Screw - 1/4-1 Valve Coated Steel, Slotted Adjustment Screw - 1 ½ - 2 Valve PVC Adjustment Screw - 1 ½ - 2 Valve Coated Steel PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV PV /4" Valve Body PVC 1/4" T-Series Valve Body PVC, 1/4" Valve Body PP 1/4" T-Series Valve Body PP 1/4" Valve Body PTFE 1/4" T-Series Valve Body PTFE 1/4" Valve Body PVDF 1/4" T-Series Valve Body PVDF 1/4" Valve Body 316 SS 1/4" Valve Body Alloy 20 1/4" Valve Body Hast C 1/4" Valve Body CPVC 1/4" T-Series Valve Body CPVC 3/8" Valve Body PVC 3/8 T-Series Valve Body PVC, 3/8" Valve Body PP 3/8" T-Series Valve Body PP 1/4" Valve Body PTFE 3/8" T-Series Valve Body PTFE 3/8" Valve Body PVDF 3/8" T-Series Valve Body PVDF 3/8" Valve Body 316 SS 3/8" Valve Body Alloy 20 3/8" Valve Body Hast C 3/8" Valve Body CPVC 3/8" T-Series Valve Body CPVC 1/2" Valve Body PVC 1/2" T-Series Valve Body PVC 1/2" Valve Body PP 1/2" T-Series Valve Body PP 1/2" Valve Body PTFE 1/2" T-Series Valve Body PTFE 1/2" Valve Body PVDF 1/2" T-Series Valve Body PVDF 1/2" Valve Body 316 SS 1/2" T-Series Valve Body 316 SS 1/2" Valve Body Alloy 20 1/2" T-Series Valve Body Alloy 20 1/2" Valve Body Hast C 1/2" T-Series Valve Body Hast C 1/2" Valve Body CPVC 1/2" T-Series Valve Body CPVC 3/4" Valve Body PVC 3/4" Valve Body PP 3/4" Valve Body PTFE 3/4" Valve Body PVDF 3/4" Valve Body 316 SS 3/4" Valve Body Alloy 20 3/4" Valve Body Hast C 3/4" Valve Body CPVC 1" Valve Body PVC 1" Valve Body PP 1" Valve Body PTFE 1" Valve Body PVDF 1" Valve Body 316 SS 1" Valve Body Alloy 20 1" Valve Body Hast C 1" Valve Body CPVC 1 1/2" Valve Body PVC 1 1/2" Valve Body PP 1 1/2" Valve Body PTFE 1 1/2" Valve Body PVDF 1 1/2" Valve Body 316 SS 1 1/2" Valve Body Alloy /2" Valve Body Hast C 1 1/2" Valve Body CPVC 2" Valve Body PVC 2" Valve Body PP 2" Valve Body PTFE 2" Valve Body PVDF 2" Valve Body 316 SS 2" Valve Body Alloy 20 2" Valve Body Hast C 2" Valve Body CPVC BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV BPV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV PRV ITEM DESCRIPTION BPV # PRV #

135 301LFW ALL SS LIQUID FILLED Our 300 series gauge line is a high quality line of liquid filled gauges. The glycerine filling helps dampen the effects of pulsation and vibration, while also perpetually lubricating the movement (and keeping contaminates such as dirt away from all moving parts) which will extend the life of the gauge. This gauge has been specifically designed with original equipment manufacturers in mind. It is typically used in chemical processing or food processing applications as well as any commercial or industrial application where stainless steel components are required. SPECIFICATIONS: Available Dial Sizes: 2 ½, 4", 6" Available Connection Sizes: 1/4"MNPT on 2, 2 ½ and 4" 1/2"MNPT on 4" and 6" Stainless Steel Case and Crimped Bezel SS Internals 316 SS Bourdon Tube & Connection Connection Welded to Case Liquid Filled (Dry Available) Accuracy : 2 ½ Dial Size = 1.5 % 4 and 6 Dial Size = 1 % Dual Scale: PSI & Bar (x100=kpa) (Single Scale available) Ambient temperature: FILLED: 30 F to 160 F DRY: -30 F to 180 F RANGE CODE Major In Minor In 30/0"VAC A /0/15 CB /0/30 CC /0/60 CD /0/100 CE /0/150 CF /0/300 CH /15 B /30 C /60 D /100 E /160 F /200 G /300 H /400 I /500 J /600 K /800 L /1000 M /1500 N /2000 O /3000 P /4000 Q /5000 R /6000 S /10,000 U /15,000 V Some ranges not available in all dial sizes, please call with your particular application A B C D E 2 ½" In /4 Dial MM NPT 4" In /4" or Dial MM ½ npt 6" In /4 or Dial MM ½ npt Page 29

136 *Blacoh GUARANTEES it's Sentinel Diaphragms and Seal bodies for three years from the date of purchase. If any failure occurs, Blacoh will replace your Diaphragm Seal at no cost to you! (Guarantee does not apply to gauges or custom models) SENTINEL DIAPHRAGM SEAL Available in a variety of chemically resistant plastics and metals SENTINEL DIAPHRAGM SEAL Protect & isolate all forms of system instrumentation from hazardous and corrosive process fluids SENTINEL FLOW THRU Prevents clogging of viscous process fluids SENTINEL "REVOLUTION" All PVC construction and threaded housings are ideal for corrosive environments USE A DIAPHRAGM SEAL TO: Protect & isolate all forms of system instrumentation from hazardous and corrosive process fluids Ensure gauge and switch accuracy Smooth out erratic pressure surges Extend the life of pressure instrumentation Protect gauges from freezing and slurries Receive accurate and consistent readings when working with corrosive or solids-laden fluids Replace expensive gauges with low cost utility gauges SENTINEL FEATURES: Three year guarantee on diaphragms & seal bodies Accuracy of ± 2% full deflection or better Pressure ranges up to 1000 PSI (68.95 BAR) 1/4" (6.35 mm) up to 3/4" (19.05 mm) inlet ports All standard models available from stock Bodies available in a full range of chemically resistant materials Custom models available (800)

137 SENTINEL DIAPHRAGM SEALS Plastic Diaphragm Seal Metal Diaphragm Seal BODY MATERIALS: POLYPROPYLENE PVC PVDF DIAPHRAGM MATERIALS: PTFE EPDM VITON BODY MATERIALS: 316 STAINLESS STEEL ALLOY 20 HASTELLOY C DIAPHRAGM MATERIALS: PTFE EPDM VITON Flow-Thru Diaphragm Seal "Revolution" Diaphragm Seal BODY MATERIALS: PVC POLYPROPYLENE TUBE DIAPHRAGM MATERIALS: EPDM VITON BODY MATERIALS: PVC DIAPHRAGM MATERIALS: EPDM VITON Please call your local distributor: L-255 3/04 Call for your FREE Demonstration CD 601 Columbia Ave., Bldg. D, Riverside, CA USA Tel: (800) or (951) Fax: (951) sales@blacoh.com Website:

138 PARTS LISTING AND EXPLODED VIEW SENTINEL MODEL RC00T-18-5 SENTINEL MODEL #: MAXIMUM PRESSURE: WETTED HOUSING: NONWETTED HOUSING: FILL DIAPHRAGM MATERIAL INLET: RC00T PSI CPVC CPVC GLYCERIN PTFE 1/2" FNPT DESCRIPTION ITEM PART # QTY Component Material Wetted Housing CPVC Diaphragm PTFE O-Ring EPDM Nonwetted Housing CPVC 5 G18 1 Gauge Stainless Steel -Brass - Liquid Filled 1/16/2008 ITEM DIMENSIONAL DRAWING TOLERANCE ±.25" BLACOH FLUID CONTROL, INC RIVERSIDE, CA USA TEL: or Fax: sales@blacoh.com web site:

139 CPVC SCHEDULE 80 FITTINGS 80C Performance Engineered and Tested Full 1/4" Through 12" Availability Spears comprehensive line of CPVC fittings offers a variety of configurations in Schedule 80 sizes 1/4" through 12". Exceptional Chemical & Corrosion Resistance Unlike metal, CPVC fittings never rust, scale or pit, and will provide many years of maintenance-free service and extended system life. Higher Temperature Ratings High Temperature CPVC Thermoplastics can handle fluids at service temperatures up to 200 F, allowing a wide range of process applications, including hot corrosive liquids. Higher Flow Capacity Smooth interior walls result in lower pressure loss and higher volume than conventional metal fittings. Lower Installation Costs Substantially lower material costs than steel alloys or lined steel, combined with lighter weight and ease of installation, can reduce installation costs by as much as 60% over conventional metal systems. CPVC Valves SPEARS CPVC Valve products are available for total system copatability and uniformity; see SPEARS THERMOPLASTIC VALVES PRODUCT GUIDE AND ENGINEERING SPECIFICATIONS (V-4). SPEARS Schedule 80 CPVC fitting designs combine years of proven experience with computer generated stress analysis to yield the optimum physical structure and performance for each fitting. Material reinforcement is uniformly placed in stress concentration areas for substantially improved pressure handling capability. Resulting products are subjected to numerous verification tests to assure obtaining the very best CPVC fittings available. SPEARS Injection Molded Schedule & 12 Large Diameter Fittings CPVC Schedule 80 Large Diameter fittings are a special engineered product by Spears Manufacturing Company, where no applicable ASTM specification exists. Available in a variety of configurations, including Tees, 90 Elbows, 45 Elbows, Bushings and Flanges. Plus additional fabricated Schedule 80 CPVC configurations. Sample Engineering Specifications All CPVC Schedule 80 injection molded fittings shall be produced by Spears Manufacturing Company from CPVC, cell classification 23447, conforming to ASTM Standard D All CPVC Schedule 80 fittings shall be listed for potable water service by the National Sanitation Foundation (NSF) and manufactured in strict compliance to ASTM F 437 for threaded fittings and ASTM F 439 for socket type fittings and Spears specifications for 10 and 12 fittings. All CPVC flanges shall be designed and manufactured to meet CL150 bolt pattern specifications per ANSI Standard B16.5 and rated for a maximum internal pressure of 150 psi, non-shock at 73 F. PROGRESSIVE PRODUCTS FROM SPEARS INNOVATION & TECHNOLOGY Visit our web site:

140 CPVC Thermoplastic Material Temperature Pressure De-rating Elevated temperature fluid mediums require a de-rating of thermoplastic pipe maximum internal pressure ratings at 73 F. To determine the maximum internal pressure rating at an elevated temperature, simply multiply the product pressure rating at 73 F by the percentage specified for the desired temperature. System Operating Temperature F ( C) CPVC (23-27) (32) (38) (43) (49) (54) (60) (66) (71) (77) (82) (88) (93) (99) 100% 92% 82% 77% 65% 62% 50% 47% 40% 32% 25% 22% 20% -0- CPVC Basic Physical Properties ASTM Test Properties Method CPVC Mechanical Properties, 73 F Specific Gravity, g/cm 3 D Tensile Strength, psi D 638 8,000 Modulus of Elasticity, psi D ,000 Compressive Strength, psi D ,100 Flexural Strength, psi D ,100 Izod Impact, notched, ft-lb/in D Thermal Properties Heat Deflection Temperature, F at 66 psi D Thermal Conductivity, BTU/hr/sq ft/ F/in C Coefficient of Linear Expansion, in/in/ F D x 10-5 Flammability Limiting Oxygen Index, % D UL 94 Rating V-0, 5VB, 5VA Other Properties Water Absorption, % 24 hr. D Industry Standard Color Medium Gray ASTM Cell Classification D NSF Potable Water Approved Yes CPVC Chemical Resistance Weak acids Strong acids Weak bases Strong bases Salts Aliphatic Solutions Halogens Strong Oxidants Excellent Excellent Excellent Excellent Excellent Good Good-Fair Good-Fair CPVC is not recommended for use with chlorinated or aromatic hydrocarbons, esters, or polar solvents such as ketones. NOT FOR USE WITH COMPRESSED AIR OR GASES Spears Manufacturing Company DOES NOT RECOMMEND the use of thermoplastic piping products for systems to transport or store compressed air or gases, or the testing of thermoplastic piping systems with compressed air or gases in above and below ground locations. The use of our product in compressed air or gas systems automatically voids any warranty for such products, and its use against our recommendation is entirely the responsibility and liability of the installer. WARNING: DO NOT USE COMPRESSED AIR OR GAS TO TEST ANY PVC OR CPVC THERMOPLASTIC PIPING PRODUCT OR SYSTEM, AND DO NOT USE DEVICES PROPELLED BY COMPRESSED AIR OR GAS TO CLEAR SYSTEMS. THESE PRACTICES MAY RESULT IN EXPLOSIVE FRAGMENTATION OF SYSTEM PIPING COMPONENTS CAUSING SERIOUS OR FATAL BODILY INJURY. SPEARS MANUFACTURING COMPANY CORPORATE OFFICES Olden Street, Sylmar, CA P.O. Box 9203, Sylmar, CA (818) PACIFIC SOUTHWEST Olden Street Sylmar (Los Angeles), CA P.O. Box 9203, Sylmar, CA (818) (800) FAX: (818) NORTHWEST 4103 C St. NE Suite 200 Auburn (Seattle), WA (253) (800) Fax (253) ROCKY MOUNTAIN 4880 Florence Street Denver, CO (303) (800) FAX: (303) SOUTH CENTRAL 4250 Patriot Dr. Suite 300 Grapevine (Dallas), TX (972) (800) Fax (972) UTAH 1641 South 700 West Salt Lake City, UT (801) Fax (801) NORTHEAST 590 Industrial Dr. Lewisberry (Harrisburg), PA (717) (800) Fax (717) SOUTHEAST 4205 Newpoint Place, Suite 100 Lawrenceville, GA (678) (800) FAX: (678) FLORIDA 3445 Bartlett Boulevard Orlando, FL (407) (800) FAX: (407) MIDWEST 1 Gateway Ct., Suite A Bolingbrook (Chicago), IL (630) (800) Fax (630) INTERNATIONAL SALES Olden Street Sylmar (Los Angeles), CA P.O. Box 9203 Sylmar, CA (818) FAX: (818) export@spearsmfg.com Copyright 2003 Spears Manufacturing Company. All Rights Reserved. Printed in the United States of America 08/03. 80C

141 DWG No REV A 1/2" CPVC/VITON NPT VENTED BALL VALVE PRODUCT OUTLET 2-1/2" 316 SST PRESSURE GAUGE WITH CPVC/PTFE ISOLATOR (0-160 PSIG) /2" CPVC BACK PRESSURE VALVE (ADJUSTABLE 0-150PSIG) 1/2" CPVC PRESSURE RELIEF VALVE (ADJUSTABLE 0-150PSIG) 2 TYP SIGMA 1 SERIES METERING PUMP S1CAH12035PVT0070UDC100C MAX. CAPACITY: PSIG 2 TYP NEMA 4X FRP TERMINAL BOX KIT P/N PLAN VIEW /2" CPVC/VITON NPT VENTED BALL VALVE PRODUCT INLET 164mL CPVC/VITON PULSATION DAMPENER 2 TYP PIPING SCHEMATIC 1/2" CPVC/VITON WYE-STRAINER BLACK UV PROTECTED POLYPROPYLENE STAND NOTES: 1. ALL PIPING AND FITTINGS SHALL BE 1/2" SCH. 80 CPVC SOCKET WELD WITH VITON SEALS UNLESS OTHERWISE REQUIRED BY COMPONENTS. 2. ALL BALL VALVES TO BE VENTED. 3" X 3" X 1/4" X L" FRP WITH HOLES ANGLE 2 TYP 3. QUANITY OF (1) SPARE PART KIT, PN , TO BE SHIPPED LOOSE WITH SKID ISOMETRIC VIEW 4. ALL DIMENSIONS ARE IN INCHES AND ARE SHOWN FOR REFERENCE ONLY A 08/11/10 AS BUILT ALS 0 05/12/10 FIRST ISSUE ALS REV CUSTOMER JOB No TITLE DATE P2_S1CA_CPVC_SODIUM HYPO DOSING SKID GENERAL ARRANGEMENT ENGINEERS SEAL ATLANTIC PUMP & ENGINEERING INC. (AWD/LWD LAKE Aub. PMP STAT) DESCRIPTION REVISIONS PURCHASE ORDER No BY THIS DRAWING IS THE PROPERTY OF PROMINENT FLUID CONTROLS INC. AND SHALL NOT BE COPIED OR TRANSFERRED WITHOUT THE WRITTEN CONSENT OF PROMINENT FLUID CONTROLS INC. ProMinent THE PROMINENT GROUP OF COMPANIES APPD REVD R PITTSBURGH, PA USA FRONT VIEW SIDE VIEW MAXIMUM TESTING PRESSURE = MAXIMUM OPERATING PRESSURE = CHEMICAL SERVICE = SODIUM HYPO 150 PSI 145 PSI DWG No PROMINENT FLUID CONTROLS LTD. 490 SOUTHGATE DRIVE. GUELPH, ONTARIO, CANADA N1H 6J3 TEL FAX DESIGNED DRAWN CHECKED ALS ALS KBP PROMINENT FLUID CONTROLS INC. RIDC PARK WEST 136 INDUSTRY DRIVE, PITTSBURGH P.A., USA TEL APPROVED SCALE DATE REV A FAX N.T.S. 05/12/10 PAGE 1/1

142 DWG No A REV B ITEM QUANTITY UOM PART PART DESCRIPTION NUMBER NUMBER 10 1 PC PFC TERMINAL BOX 2 PUMP 20 1 PC HUBBEL 15A/120VAC HBL5262 DUPLEX RECPT 30 1 PC RECEPTACLE COVER, RAINTIGHT, MULTI USE 40 1 PC SINGLE PVC ELECT. GANG BOX W/1/2" PORT 50 2 FT /2" PVC SCH40 RIDGID CONDUIT GRAY 60 1 PC ADAPTOR MALE, ELECTRICAL, PVC 1/ PC GALV ROMEX NUT 1/2" FOR STRAIN RELIEF 80 2 PC /2" CORD GRIP 2 HOLE X 0.24" 90 1 PC /2" RNC FLAT WASHER FT SD1.5X1" SOLID BLACK WIRE DUCT FT TC1.5" SOLID BLACK WIRE DUCT COVER PC /8" PVC, SOLID SQUARE BAR STOCK SEE NOTE MIN MAX SEE NOTE NOTES: 1. THIS DIMENSION CAN VARY FROM 6.00" TO 24.00" DEPENDING UPON THE APPLICATION. 2. ALL DIMENSIONS ARE IN INCHES AND ARE SHOWN FOR REFERENCE ONLY. 3. THE LOCATION OF ITEM 80 WILL VARY WITH EACH SKID AND WILL BE DETERMINED BY THE SKID LAYOUT DURING INSTALLTION.. 4. ITEMS 100, 110 AND 120 ARE NOT SHOWN. THE LOCATION OF THESE ITEMS WILL VARY WITH EACH SKID AND WILL BE DETERMINED BY THE SKID LAYOUT DURING INSTALLATION. 5. WHEN ORDERED WITH AS PART OF A SKID, ALL PARTS WILL BE CUT AND INSTALLED ON THE SKID. OTHERWISE, ALL PARTS WILL BE CUT AND INSTALLED IN THE FIELD. B 02/27/08 UPDATED ITEM DESCRIPTION GJS A 07/03/07 UPDATED BOM TO CURRENT STANDARDS GJS 0 08/15/06 FIRST ISSUE GJS REV DATE DESCRIPTION BY APPD REVD REVISIONS CUSTOMER JOB No TITLE 2 PUMP TERMINAL BOX KIT WITH NON-GFCI RECEPTACLE GENERAL ARRANGEMENT ENGINEERS SEAL PROMINENT FLUID CONTROLS INC PURCHASE ORDER No THIS DRAWING IS THE PROPERTY OF PROMINENT FLUID CONTROLS INC. AND SHALL NOT BE COPIED OR TRANSFERRED WITHOUT THE WRITTEN CONSENT OF PROMINENT FLUID CONTROLS INC. ProMinent THE PROMINENT GROUP OF COMPANIES R A FRONT VIEW SECTION A-A 40 ISOMETRIC VIEW DWG No PROMINENT FLUID CONTROLS LTD. 490 SOUTHGATE DRIVE. GUELPH, ONTARIO, CANADA N1H 6J3 TEL FAX DESIGNED DRAWN CHECKED PITTSBURGH, PA USA GJS GJS JMS PROMINENT FLUID CONTROLS INC. RIDC PARK WEST 136 INDUSTRY DRIVE, PITTSBURGH P.A., USA TEL APPROVED SCALE DATE REV B FAX N.T.S. 08/15/06 PAGE 1/1

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144 Maintenance Summary Form Project: Equipment Item: Chemical Metering Pump: Chemical Service: Mechanical Dwg: AWD/LWD Lake Aub. Pump Station CDM Constructors, Inc. Atlantic Pump & Engineering Inc. P2_S1CA_CPVC_SODIUM HYPO S1CAH12035PVT Metering Pump SODIUM HYPOCHLORITE A-200 Equipment Identification Number(s): Equipment Tag No. Equipment Serial No. P2_S1CA_CPVC_SODIUM HYPOCHLORITE Drive Tag No. Drive Serial No. N/A N/A Motor Data 1/8HP 50/60HZ,.09kW IP55, IEC FRAME, TEFC 230V, 3 PH, 0.7A Drive Total Weight: Appr. 24 lbs each Manufacturer: Name: Mailing Address: Prominent Fluid Controls Inc. RIDC Park West 136 Industry Drive Pittsburgh PA, Phone Number: Fax Number: Manufacturer s Local Representative: Company Name: Atlantic Pump & Equipment Inc. Mailing Address: PO Box 110 Sanford, ME Phone Number: Fax Number:

145 Maintenance & Lubrication Form Project: Equipment Item: Chemical Metering Pump: Chemical Service: Mechanical Dwg: AWD/LWD Lake Aub. Pump Station CDM Constructors, Inc. Atlantic Pump & Engineering Inc. P2_S1CA_CPVC_SODIUM HYPO S1CAH12035PVT Metering Pump SODIUM HYPOCHLORITE A-200 Manufacturer s Maintenance Requirements: General Recommendation For Maintenance Intervals - Every (3) Months Maintenance Operation Equipment location Frequency / Quantity Regular Inspections Drive Unit 3 Month Intervals Inspect Bearings & Gearing Drive Gear Box PACKED/SEALED BEARINGS/NO FUTURE LUBRICATION Tightening Liquid End Liquid End Initial after 24hrs Operation/3 Month Intervals Changing Gear Oil Drive Gear Box N/A Lubricant List: Generic Lubricant Type PACKED/SEALED BEARINGS/NO FUTURE LUBRICATION Manufacturer / Product Name Viscosity Class

146 Recommended Spare Parts Summary Form Project: Equipment Item: Chemical Metering Pump: Chemical Service: Mechanical Dwg: AWD/LWD Lake Aub. Pump Station CDM Constructors, Inc. Atlantic Pump & Engineering Inc. P2_S1CA_CPVC_SODIUM HYPO S1CAH12035PVT Metering Pump SODIUM HYPOCHLORITE A-200 Part Description Quantity Part Number S1CAH12035PVT Spare Parts Kit mL CPVC/Viton Pulsation Dampener - Spare Bladder /2" CPVC BPV/PRV Spare Parts Kit Closest Parts & Service Center: Company Name: Atlantic Pump & Engineering Inc. Mailing Address: PO Box 110 Sanford, ME Phone Number: Fax Number:

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