MAINTENANCE MANUAL DI 16 0.2-1.6% Press Ctrl + L for full screen 1
STANDARD INSTALLATION Inlet Outlet Optional accessories: Pressure regulator Solenoid valves Water meter Flow restrictor 200 Mesh/ 80 micron filter Concentrate Optional accessories Union ball check/ check valve or water hammer arrestor 2
MAIN MENU CHAPTER 1 Removing the dispenser from the installation CHAPTER 2 Disassembling the dispenser CHAPTER 3 Reassembling the dispenser CHAPTER 4 Maintenance of PX piston CHAPTER 5 Maintenance of air bleed CHAPTER 6 Troubleshooting guide «click» on the desired Chapter or «click» for next slide 3
SPECIFICATIONS Injection Range: 1:500 (0.2%) to 1:64 (1.6%) Water Flow Range: 0.05 to 11 GPM Operating Water Pressure: 4.3 to 85 PSI Maximum Water Temperature: 104 F 40 C Note: Normal safety precautions should be practiced when working with chemicals and equipment. 4
CHAPTER 1 REMOVING THE DISPENSER FROM INSTALLATION «Click» to go back to the main menu «Click» for next slide 5
DISASSEMBLING OF THE DISPENSER FROM THE INSTALLATION After turning off the water and relieving the pressure on the unit, unscrew the dispenser inlet/outlet couplings and allow it to drain. Unscrew the suction tube nut and remove the hose. 6
CHAPTER 2 DISASSEMBLING THE DISPENSER «Click» to go back to the main menu «Click» for next slide 7
DISASSEMBLING THE DISPENSER Unscrew middle retaining nut. 8
DISASSEMBLING THE DISPENSER Pull the injection stem assembly out of the injection sleeve, and let the solution drain out of it. Caution: Stem may be full of undiluted chemical. Be aware of hazardous materials and take the necessary precautions for protection. WATCH OUT FOR SPLASHING! 9
DISASSEMBLING THE DISPENSER With the injection stem assembly in your hands, unscrew the check valve nut. 10
DISASSEMBLING THE DISPENSER Gently push the check valve out of the dosing stem with a pencil or similar object. Do not scratch the inside of the dosing stem. 11
DISASSEMBLING THE DISPENSER Separate the check valve assembly. Remove the check valve retainer with the help of small flat head screw driver. Then, remove the cone and the spring. 12
DISASSEMBLING THE Y OF DISPENSER Unscrew the bell housing and remove it. 13
DISASSEMBLING THE DISPENSER Unscrew the plunger by pushing the piston down as far as possible. Use the narrow end of the suction tube nut as a tool to unscrew the plunger. 14
DISASSEMBLING THE DISPENSER Remove the piston assembly. 15
DISASSEMBLING THE DISPENSER Unscrew the injection sleeve from the body of the dispenser. Check that the O-ring, retainer and seal are on the injection sleeve. If not, remove them from the inside of the dispenser. 16
DISASSEMBLING THE DISPENSER Remove the screen from the body, put the dispenser body on a table, hold it firmly and at the same time lift the screen with your fingers. Remove the bell housing seal. 17
DISASSEMBLING THE DISPENSER Disassembly of the diffuser assembly is only necessary if a leak develops. Unscrew the diffuser nut. Push the diffuser towards the interior of the dispenser. Bump it with your palm if necessary. Remove the diffuser assembly. 18
DISASSEMBLING THE DISPENSER CLEANING & MAINTENANCE PROCEDURE When the disassembly of the Dosatron unit is complete, soak it in lukewarm soapy water. A soft bristled brush may be used to break residue. Change seal kit every 12 months. Seal kit part No. EDDI002 includes: JDI012 - Top O-ring JDI011 - Top seal JDI010 - Plunger seal JDI009 - Injection stem O-ring MDI028 - Check valve spring PDI032 - Check valve cone JDI011 - Check valve seal JDI012 - Check valve O-ring 19
CHAPTER 3 REASSEMBLING THE DISPENSER «Click» to go back to the main menu «Click» for next slide 20
REASSEMBLING THE DISPENSER Place the screen inside the body. Then, reseat or replace the bell housing O-ring. Replace the O-ring if leaking. 21
REASSEMBLING THE DISPENSER If the diffuser is leaking, replace the diffuser O-ring. Install the diffuser assembly into the body. Be sure to align the notch in the diffuser with the tooth that is molded in the body. Install the diffuser nut hand tight. 22
Injection Assembly REASSEMBLING THE DISPENSER Replace the check valve O-ring. Replace the check valve seal on the barb fitting with the raised portion facing upward. 23
Injection Assembly REASSEMBLING THE DISPENSER Replace the check valve cone and spring. Insert them in the check valve guide. Then, put the check valve retainer to hold the cone and the spring in place. Caution: Small, spring loaded parts are easily lost! 24
Injection Assembly REASSEMBLING THE DISPENSER Assemble the check valve assembly by firmly pushing the guide and the barbed fitting together. 25
Injection Assembly REASSEMBLING THE DISPENSER Replace the injection stem O-ring. 26
Injection Assembly REASSEMBLING THE DISPENSER Insert the check valve assembly into the injection stem. Slide the middle nut on the stem and thread the check valve nut. 27
Injection Sleeve Assembly REASSEMBLING THE DISPENSER Replace the injection seal on the injection sleeve. Make sure the raised part is facing up. Put the top seal retainer with the ridge toward the seal. 28
Injection Sleeve Assembly REASSEMBLING THE DISPENSER Replace the sleeve O-ring on the top of the retainer. Thread the injection sleeve assembly into the body of the dispenser. 29
Plunger Assembly REASSEMBLING THE DISPENSER Replace the plunger seal. Make sure not to damage the seal or plunger. 30
Plunger Assembly REASSEMBLING THE DISPENSER Push the piston down as far as possible and screw the plunger onto the plunger rod. Use the narrow end of the suction tube nut as a tool to screw the plunger all the way until it stops. 31
REASSEMBLING THE DISPENSER Insert the piston assembly. 32
REASSEMBLING THE DISPENSER Screw the bell housing onto the body of the dispenser. It should be hand tight. 33
REASSEMBLING THE DISPENSER Insert the injection stem assembly into the sleeve. Insert the stem ring into the sleeve assembly until flush. Align tooth on sleeve with a notch in clear adjusting nut. 34
REASSEMBLING THE DISPENSER Thread the middle nut onto the injection sleeve. 35
REASSEMBLING THE DISPENSER The dispenser is ready to be reinstalled. 36
CHAPTER 4 MAINTENANCE OF PX PISTON «Click» to go back to the main menu 37
MAINTENANCE OF PX PISTON Piston Fit Test Insert upper portion of piston into the bell housing half way down, turn the bell housing upside down and hold the smaller part of the piston ONLY, then lift it. The piston should be snug in the bell housing and the bell housing should not fall off, if it does the upper piston shell needs to be replaced. Also inspect the inside of the bell housing and look for deep vertical scratches. If this is the case, the bell housing needs to be replaced. 38
Piston Fit Test MAINTENANCE OF PX PISTON Note: It is best to remove the plunger (page 14) prior to doing this test so it will not interfere. Insert the lower part of the piston half way down the body. Holding onto the top of the piston, let go of the body. The piston should be snug in the body, and the body should not fall off, if it does the lower piston shell needs to be replaced. Also inspect the inside of the body and look for deep vertical scratches. If this is the case, the body needs to be replaced. 39
Disassembly of piston MAINTENANCE OF PX PISTON Remove the plunger rod. To do so, turn the nut 1/8 turn counter clockwise. Pull on nut once, then, turn again the nut 1/8 turn counter clockwise. 40
Disassembly of piston MAINTENANCE OF PX PISTON Remove the upper valves by squeezing the upper area of the valve. 41
Disassembly of piston MAINTENANCE OF PX PISTON Unscrew the 4 screws that connect the piston rod retainer to piston shell. Remove the piston rod retainer. Pull out the actuator assembly from the top. 42
Disassembly of piston MAINTENANCE OF PX PISTON Remove screws from outer perimeter of piston shell. Separate the upper piston shell from the lower piston shell. Remove the seal between the two piston shells. 43
Reassembly of piston MAINTENANCE OF PX PISTON Replace the seal between the two piston shells. Put together the upper and the lower piston shells. Screw the screws from outer perimeter of piston shell. 44
Reassembly of piston MAINTENANCE OF PX PISTON Replace the lower valves O-rings if they are missing or deteriorating. Replace the toggle spring. Insert the piston assembly into the piston shell. Make sure that the two guides are aligned with the piston shell columns. 45
Reassembly of piston MAINTENANCE OF PX PISTON Put together the piston rod retainer, the two feet should face downward. Install the piston rod retainer in the piston shell. Attach it with the four screws. 46
Reassembly of piston MAINTENANCE OF PX PISTON Replace the O-rings on the upper piston valves if they are missing or deteriorating. Insert the two upper piston valves. The splits in the valves should line up. 47
Reassembly of piston MAINTENANCE OF PX PISTON Install plunger rod in the rod retainer. The pin in the head of the rod should be aligned with the slot inside the rod retainer. Lock it in to place by turning the lock nut clockwise 1/8 turn, pushing it down and 1/8 turn clockwise again. 48
MAINTENANCE OF PX PISTON Reset Piston To reset the piston, remove the bell housing, push the piston all the way down, it may click, pull the piston all the way up. Holding it in up position, push down on the vertical posts and it should click. Push the piston back down and screw the bell housing on. 49
CHAPTER 5 MAINTENANCE OF AIR BLEED «Click» to go back to the main menu «Click» for next slide 50
Disassembly of air bleed MAINTENANCE OF AIR BLEED Remove the rubber cap from the top of the air bleed button. 51
Disassembly of air bleed MAINTENANCE OF AIR BLEED Using a small flat blade screwdriver, gently pry loose the ribbed collar. Remove the ribbed collar by pulling it straight up. 52
Disassembly of air bleed MAINTENANCE OF AIR BLEED Gently twist the air bleed button with pliers (if necessary) until the two tabs on the air bleed button align with the corresponding grooves in the bell housing. Remove the air bleed button by pushing it through the bell housing. 53
Reassembly of air bleed MAINTENANCE OF AIR BLEED Replaced the O-ring. The only serviceable part on the air bleed is the O-ring. 54
Reassembly of air bleed MAINTENANCE OF AIR BLEED Align the two tabs on the air bleed with the corresponding grooves in the bell housing. 55
Reassembly of air bleed MAINTENANCE OF AIR BLEED Install the air bleed button from the inside of the bell housing. Make sure the two tabs get out of the bell housing. Rotate the air bleed button a quarter turn. 56
Reassembly of air bleed MAINTENANCE OF AIR BLEED Install the ribbed collar so that the tabs fit into the slots in the collar. Re-install the rubber cap on the air bleed button. 57
CHAPTER 6 TROUBLESHOOTING GUIDE «Click» to go back to the main menu «Click» for next slide 58
TROUBLESHOOTING SYMPTOM PISTON Piston is not clicking Excessive water flow Water hammer CAUSE The unit is installed in the wrong direction Piston locked up/not clicking or bypass is in OFF position. Presence of air inside the bell housing In-line water filter or inside screen is clogged Worn piston shells, bell housing or body Scratched/scored piston shells, bell housing and/or body REMEDY The arrow on the unit should point in the same direction as the water flow. Water supply and demand valve should be open. Reset piston. See page 49 for instructions. Flip bypass to ON position if dispenser is equipped with manual bypass Bleed out the air by pushing the air bleed button until constant flow of water comes out from around the button. 1. Reduce the flow rate and restart the unit slowly. 2. Open bell housing, check O-rings around the four piston valves (2 at the top, 2 at the bottom) to see if they are missing or dislodged. 3. Reset the piston (see page 49 for instructions) screw bell housing back on. Reset piston (see page 49 for instructions) and install water hammer arrestor in the appropriate location. Clean the in line water filter. Clean the inside screen (see pages 17 and 21). Do piston fit test (pages 38-39). Replace piston shells, body and bell housing as necessary. Make sure your installation has a 200 mesh filter before the Dosatron. Do piston fit test (pages 38-39). replace piston shells, body and bell housing as necessary. Make sure your installation has a 200 mesh filter before the Dosatron. 59 COPYRIGHT, DOSATRON INTERNATIONAL S.A., 2002
TROUBLESHOOTING SYMPTOM DOSING Water flowing back into solution container. No suction of solution CAUSE Check valve dirty, worn, assembled incorrectly or missing Piston locked up/not clicking or bypass is in OFF position Air leak in the suction tube Suction tube or strainer clogged Check valve worn, improperly assembled, dirty or damaged Plunger seal is damaged, swollen or missing Worn piston shells, bell housing or body REMEDY Clean or replace check valve parts and reassemble check valve correctly. Be sure the check valve seal is in proper position. Pages 23-25. Reset piston. See page 49 for instructions. Flip bypass to ON position if dispenser is equipped with manual bypass Check suction tube connection. Inspect suction tube for pin holes or cracks. Check tightness of connection nuts. Cut ½ of top of the hose and reattach it correctly. Clean suction tube and strainer or replace hose assembly. Raise strainer 2 off the bottom of stock tank solution. Clean or replace check valve parts. In particular the seal and the cone. Pages 23-25. Clean or replace plunger seal. If plunger seal is missing, check incoming water pressure; refer to unit manual for specifications. Do piston fit test (pages 38-39). If necessary replace piston shells, body and bell housing. Make sure your installation has a 200 mesh filter before the Dosatron. 60 COPYRIGHT, DOSATRON INTERNATIONAL S.A., 2002
TROUBLESHOOTING SYMPTOM Under-Injection Worn or scratched piston shells, bell housing and/or body Suction of air CAUSE Excessive water flow Worn plunger seal Worn or cracked injection stem Check valve worn, improperly assembled, dirty or damaged Do piston fit test (pages 38-39). If necessary replace piston shells, bell housing and/or body. Make sure your installation has a 200 mesh filter before the Dosatron. Check suction tube connection. Inspect suction tube for pin holes or cracks. Check tightness of connection nuts. Cut ½ off top of the hose and reattach it correctly. Listen to the unit clicking, count the individual clicks, should not exceed 36 clicks in 15 seconds otherwise is excessive flow. If excessive flow reduce the flow rate and restart the unit slowly. Replace plunger seal. Replace injection stem. REMEDY Clean or replace check valve parts. In particular the seal and the cone. Pages 23-25. 61 COPYRIGHT, DOSATRON INTERNATIONAL S.A., 2002
TROUBLESHOOTING SYMPTOM LEAKS Leaks in the vicinity of the black nut under the body Leaks between the body and the bell housing CAUSE Diffuser seal is damaged or positioned incorrectly Diffuser is installed incorrectly Body may be cracked Bell housing seal is damaged, positioned incorrectly or missing REMEDY Position correctly or replace the diffuser seal. Check tightness of the nut. Pages 18 & 22. Position correctly or replace the diffuser if damaged. Align notch in the diffuser with tooth molded in the body. Pages 18 & 22. Check and replaced the body if necessary. Position correctly, clean the seal seat, or replace the bell housing seal. 62 COPYRIGHT, DOSATRON INTERNATIONAL S.A., 2002
Thank you for using Dosatron liquid dispensers. Please contact us at (800) 523-8499 for further assistance or visit our website at www.dosatronusa.com 2090 Sunnydale Blvd., Clearwater, Florida 33765 63