CHEMPOD
Table of Contents Overview... 3 Specifications... 3 Dimensions... 3 Weight... 3 Electrical Voltage... 3 Capacity... 3 Product Supply... 3 Pneumatic Supply... 3 Optional Installation Kits... 3 Locating and Mounting the ChemPod... 4 Air and Fluid Connections... 6 Application Plumbing with A Mizer... 7 Application Plumbing Other than a Mizer... 7 Hose Pressure Loss Chart... 8 Electrical... 10 Controller Diagram... 10 Controller Status... 11 Control Wiring... 11 Schematic ChemPod Wiring Diagram... 13 Schematic ChemPod To Mizer Wiring Diagram... 14 ChemPod Parts Diagram... 15 P91030001 ChemPod Parts Listing... 16 Application Examples... 17 Wheel Cleaner Application... 17 High Flow Application... 18 Hand Wand Application... 19 Self-Serve Bay Application... 20 ChemPod Accessories... 21 P91030002 - ChemPod Mizer Install Kit... 21 P91030003 - ChemPod Air Regulator Kit... 22 P20040003 - Sump Wrench for Sump Housing... 23 P91030005 - ChemPod Accessory 3/8" Valve Plumbing... 24 Troubleshooting... 25 ChemPod Controller/Float Switch... 25 Air Only, Exiting ChemPod... 27 Will Not Fill... 27 Overfilling... 27 Pressure Fluctuating... 27 Air Bleeding/Leaking... 27 Cleaning Systems Inc. 2 P59000002 Rev:03
Overview The ChemPod is a solution storage reservoir that holds a solution in a pre-charged, ready to apply state. It has its own control module and fluid level switch to maintain an operable fluid level while maintaining a consistent output pressure. The unit can be hooked up to multiple application devices. The ChemPod will provide a consistent fluid flow of product whether in diluted form or non-diluted form to the applicator creating even coverage allowing an economical application of product. The ChemPod can also be used to apply products that require air injection agitation of product at the applicator(s) providing extended coverage on surfaces using less product. Specifications Dimensions ChemPod assembly with cover: 11 wide x 26 tall x 8" deep Weight 8.0 pounds (empty) Electrical Voltage 24VAC 50/60Hz Capacity 1 Gallon Product Supply Maximum Product Temperature: 120 F Pneumatic Supply 60PSI Maximum @ 0.2SCFM per ChemPod Optional Installation Kits P91030002 ChemPod Mizer Install Kit. Kit includes fluid plumbing components to connect ChemPod to Mizer outlet and tubing to connect to an air source. P91030003 ChemPod Regulator Install Kit. Kit includes a pneumatic regulator and tube fittings to control the air pressure in the ChemPod(s). Cleaning Systems Inc. 3 P59000002 Rev:03
Locating and Mounting the ChemPod The ChemPod location is specific to where and how the product is to be applied. It can be mounted directly to or at the application mechanism, or out of customers view in an equipment room or some other controlled environment. Consideration to temperature is also a factor in colder or extremely warm environments. The ChemPod can handle temperatures between 32 to 120 F, but preferably around (room temperature) 70 F. The distance the supply lines run from the ChemPod to the applicator is one of the more important considerations. It is recommended to try to keep the length of the lines between the ChemPod and the applicator under 75 feet, although longer connections will work, the response time, pressure losses, and opportunity for larger product loss due to line bleed down become more prevalent in long connections. The height of the ChemPod and the amount of clearance under it should be reviewed before mounting. The ChemPod must be mounted with a minimum clearance of 22 to allow adequate room to remove the ChemPod sump for maintenance. The ChemPod must be mounted vertically. The ChemPod has provisions for two 3/8" diameter fasteners to mount the ChemPod head directly to a wall or structure. Typical methods for mounting are: Concrete anchors to masonry and block walls, anchoring mounting tracks (Unistrut, Kindorf, etc) horizontal or vertical to catch the mount holes or a fabricated bracket. See illustration on following page. Cleaning Systems Inc. 4 P59000002 Rev:03
ChemPod Mounting Example Cleaning Systems Inc. 5 P59000002 Rev:03
Air and Fluid Connections The air regulator used must be a relieving type that will relieve the back pressure within 10psi to maintain operational consistency of the ChemPod integral quick exhaust valve. View of Air Plumbing Cleaning Systems Inc. 6 P59000002 Rev:03
Top view of air and fluid connections. Cover is removed for clarity Application Plumbing with a Mizer The following illustration shows the ChemPod fluid connection to the Mizer using the parts included in ChemPod Mizer Install Kit P91030002. The check valve connects directly to the injector outlet on the Mizer (3/8NPT). 1/2" O.D. tube is supplied for the connection from the tee to the ChemPod. The connection port for the product application line is a ½ O.D. tube compression fitting. The line routed to the application device should be sized referring to line loss chart. The line sizes should be sized large enough to prevent less than 20PSI of system back pressure caused by the plumbing to the applicator. Too large of plumbing to the applicator will cause issues with the application start up delays and product waste due to system draining down after the application shuts off. Application Plumbing Other than a Mizer The plumbing will follow the same routing as a Mizer connection. An inline check valve will be required on the pressure end (filling device) to prevent back flow. Take note of the inline check valve and flow direction in the following illustration. The filling device will have to operate at a higher pressure then the ChemPod operating pressure. The pressure differential between the filling device and the ChemPod will determine refill rate (in time). The filling device should be operating at least 20PSI higher. Cleaning Systems Inc. 7 P59000002 Rev:03
3/8 NPT CONNECTION AT THE INJECTOR OUTLET. NOTE THE CHECK VALVE FLOW DIRECTION ½ O.D. TUBE TO APPLICATION ½ O.D. TUBE TO CHEMPOD INLET/OUTLET Mizer fluid connection. Mizer cover removed for clarity Hose Pressure Loss Chart The chart below shows the pressure drop in PSI per 100FT of hose with typical water flow rates. Example: A 100' long 3/8 hose flowing 3 gallons of water per minute has a 50PSI pressure loss. A 50 long piece of the same hose and flow would have a 25PSI pressure loss. Most installations use a hose or tube from the ChemPod to the applications, the pressure loss chart can be used as a reference to help size the proper size hose or tube. Note that if tubing is used, the chart would reference the inside diameter, as an example a standard ½ polyethylene tube will have a 3/8 inside diameter and the 3/8 column of the chart should be used. Try to keep the plumbing runs from the Mizer panel to the application as short as possible to prevent pressure loss, heat loss, and improve your reaction time on and off reducing waste. As an average, most plumbing distances from the Mizer panel to the applicator are less than 50 ft. runs. Cleaning Systems Inc. 8 P59000002 Rev:03
Pressure loss chart Cleaning Systems Inc. 9 P59000002 Rev:03
Controller Diagram Electrical K2.2 K2.1 IN1.1 IN1.2 IN2.1 IN2.2 L2 K1.2 K1.1 L1 P40050011 - CONTROLLER DUAL I/O 24V CHEMPOD ITEM # DESCRIPTION NOTES/STATUS 1 24VAC power connections No polarity 2 LED (red) - Fault indicator FLASHING - Controller in Fault. Cycle power to reset 3 LED (green) - Upper float switch indicator ON - No fluid present OFF - fluid present 4 Upper float switch connections Normally closed switch 5 Lower float switch connections Normally closed switch 6 LED (green) - Lower float switch indicator ON - No fluid present OFF - fluid present 7 Relay output 2 connections Not used 8 LED (green) - Relay output 2 indicator Not used 9 LED (green) - Relay output 1 indicator ON - Chempod fill signal ON OFF - Chempod idle 10 Relay output 1 connections Normally Open contact P40050011 Controller Item Descriptions Cleaning Systems Inc. 10 P59000002 Rev:03
Controller Status The ChemPod controller P40050011 has LED s to visually indicate the state of the (2) inputs, (2) outputs, and if the controller is in a fault. See the controller diagram above for LED identification. LED (red) - Fault Indicator LED will flash red to indicate the controller is in a fault state if either of the following conditions are met: 1. Float switch error. The upper float switch is OFF (fluid present), and the lower float switch is ON (fluid not present). This state is not possible if all components are functioning properly and indicates there is an issue with the float switch or wiring. 2. The Chempod calls for a fill < 15 seconds after it finishes a fill cycle and reaches full. The ChemPod should not be draining quick enough to require a fill within 15 seconds of reaching full and shutting off. LED (green) - Upper Float Indicator LED is ON when fluid is not present. OFF when fluid is present. The float switch is a normally closed switch. LED (green) - Lower Float Indicator LED is ON when fluid is not present. OFF when fluid is present. The float switch is a normally closed switch. LED (green) - Relay Output 1 Indicator LED is ON when the normally open relay contact closes to send a signal to the filling control device to fill the ChemPod. OFF when the ChemPod is full or Idle. The relay contact is open when the LED is OFF. LED (green) - Relay Output 2 Indicator Not used for the ChemPod configuration. Control Wiring The ChemPod comes assembled with the control board and float switch wiring in place. The supplied wiring harness will connect to the right-hand side of the control board as shown in the following illustrations. IN1.1 - RED WIRE LOWER FLOAT SWITCH IN1.1 - BLK WIRE LOWER FLOAT SWITCH K1.2 - N.O. OUTPUT RED K1.1 - N.O. COMMON GREEN IN2.1 - GRN WIRE UPPER FLOAT SWITCH IN2.2 - WHT WIRE UPPER FLOAT SWITCH L1-24VAC PHASE POWER IN - BLACK L2-24VAC NEUTRAL POWER IN - WHITE Cleaning Systems Inc. 11 P59000002 Rev:03
Float switch and control module Cleaning Systems Inc. 12 P59000002 Rev:03
Schematic ChemPod Wiring Diagram Schematic ChemPod Connections Cleaning Systems Inc. 13 P59000002 Rev:03
Schematic ChemPod To Mizer Wiring Diagram Schematic Reference of ChemPod to Mizer Connection Cleaning Systems Inc. 14 P59000002 Rev:03
ChemPod Parts Diagram Cleaning Systems Inc. 15 P59000002 Rev:03
P91030001 ChemPod Parts Listing ITEM QTY NUMBER DESCRIPTION 1 1 P17020005 COVER CHEMPOD GRAY ABS 2 1 P18000005 BRACKET CHEMPOD-CONTROLLER ALUMINUM 3 1 P20030001 CHEMPOD HEAD WHITE 4 1 P20030002 CHEMPOD HEAD EXHAUST CAP 5 1 P20040002 SUMP 20" BLUE 6 1 P21020003 VALVE RELIEF 75PSI 1/4NPT BRASS 7 1 P23010007 TEE 1/4NPT FEMALExMALExFEMALE BRASS 8 1 P23090006 ADAPTOR.50TUBEx.50MPT 90DEG COMP PP 9 1 P23090007 ADAPTOR.375TUBEx.25MPT 90DEG COMP PP 10 1 P23090008 ADAPTOR.25TUBEx.25MPT 90DEG COMP PP 11 1 P23090009 ADAPTOR 1/2SLIP x 1/2MNPT SCH40 PVC WHITE 12 1 P28010004 O-RING.210x5.60ID SILICONE 70D ORANGE 13 1 P28060002A DIAPHRAGM 1.96 ODx.060" SILICONE 70D RED 14 1 P28060002B GASKET 1.96 IDx0.06"THK SILICONE 70D RED 15 1 P40030006 SWTCH FLOAT MULTIPOINT NC-3.0", NC-14.0" 16 1 P40050011 CONTROLLER DUAL I/O 24V CHEMPOD 17 1 P49020002 HARNESS CHEMPOD INTERFACE 15'LONG 18 4 P49050009 TERM DISC 22-16AWG FEM.250 FULL-INSU PK 19 1 P51000024 DECAL CHEMPOD 20 2 P51000028 DECAL CAUTION PRESSURIZED DEVICE 21 1 P51000031 DECAL CHEMPOD CONTROLLER DIAGRAM 22 1 P52020005 LABEL SPEC CHEMPOD 23 1 P52020006 LABEL SPEC ELECTRICAL CHEMPOD 24 1 P61000002-20 PIPE 1/2 SCH40 PVC WHITE 20"CUT LENGTH 25 6 P70010010 SCREW 8x3/8LG PHIL PAN THRD-FORMING SST 26 6 P70010011 SCREW 8x3/4LG PHIL PAN THRD-FORMING SST 27 3 P71040002 CABLE TIE 4.00x.100 NATURAL Cleaning Systems Inc. 16 P59000002 Rev:03
Application Examples Wheel Cleaner Application Cleaning Systems Inc. 17 P59000002 Rev:03
High Flow Application Cleaning Systems Inc. 18 P59000002 Rev:03
Hand Wand Application Cleaning Systems Inc. 19 P59000002 Rev:03
Self-Serve Bay Application Cleaning Systems Inc. 20 P59000002 Rev:03
ChemPod Accessories P91030002 - ChemPod Mizer Install Kit ITEM QTY NUMBER DESCRIPTION 1 1 P21000019 VALVE CHECK.375FPTx.375FPT PP 125PSI 2 2 P23090012 ADAPTOR.50TUBEx.38MPT COMP PP 3 1 P20010003 TUBING.50x.375 LDPE NATURAL 15' LONG 4 1 P20010008 TUBING.25X.125 LDPE NATURAL 15' LONG 5 1 P23090018 ADAPTER TEE-BRANCH.50TUBEx.38MPTCOMP PP 6 1 P23090019 ADAPTER ELBOW 90DEG.50TUBEx.38FPT COMP PP P91030002 Part Listing Cleaning Systems Inc. 21 P59000002 Rev:03
P91030003 - ChemPod Air Regulator Kit ITEM QTY NUMBER DESCRIPTION 1 1 P21010001 REGULATOR MINI 1/8&1/4NPT PORTS 0-60PSI 2 3 P23090002 ADAPTOR.25TUBEx.25MPT PP PUSHLOCK 3 1 P21010002 REGULATOR BRKT & NUT MINI PLATED-STEEL 4 1 P21040001 GAUGE 0-100 1.00DIA.125MPT CBM P91030003 Part Listing Cleaning Systems Inc. 22 P59000002 Rev:03
P20040003 - Sump Wrench for Sump Housing Wrench P20040003 used to remove the sump Cleaning Systems Inc. 23 P59000002 Rev:03
P91030005 - ChemPod Accessory 3/8" Valve Plumbing ITEM QTY NUMBER DESCRIPTION 1 3 P20010003 TUBING.50x.375 LDPE NATURAL, 10FEET 2 1 P21000021 VALVE SOLENOID.375FPT SST 24VAC SPADE 3 2 P21000025 VALVE BALL.25MPTx.25FPT PLSTC 4 1 P23000016 NIPPLE.38NPTx2.50"LONG SCH40 SST 5 1 P23010011 TEE.38FPTx.38FPTx.38FPT SST 6 1 P23010013 TEE.50T COMP PP 7 1 P23070004 PLUG.375MPT SST 302 SOCKET 8 2 P23090012 ADAPTOR.50TUBEx.38MPT COMP PP 9 2 P23090014 ADAPTER.50x.25MPT PP 10 1 P49020003 HARNESS SOLENOID SPADE 20-2 CABLE 6'LONG 11 1 P71000013 CLAMP HANGING 3/8&1/2"CONDUIT SST P91030005 Parts Listing This is an example. Each component can be purchased separately or as kit #P91030005. Cleaning Systems Inc. 24 P59000002 Rev:03
Troubleshooting ChemPod Controller/Float Switch The controller receives the fill signal from the float switch and closes the normally open contact (K1.2) to call for product to fill the ChemPod. The float switch has an upper and lower normally closed contact. When empty, the lower float contact is closed, calling for fill until the upper (normally closed) contact opens and stops the fill process. The switch must operate in that sequence or the controller will fault out and will need to be reset (by cycling the 24VAC power). It is important to keep in mind that whenever manually operating the float switches out of sequence, the controller must be reset because it has faulted out (indicated with a flashing red LED) and will not function until it is reset. To clear/reset the ChemPod controller, unplug or shut off the power source to the controller for at least 10 seconds. The power source is located on the lower right hand corner of the control module (black or white wire will disrupt power to controller). Test Float Switch: Remove the ChemPod sump to access and test the float switch. Use CAUTION and relieve any system pressure in the ChemPod before removing the sump. Check to ensure that the floats move freely. Test each float separately using an Ohm meter or continuity tester. The upper float uses the green and white wires and the lower float uses the red and black wires. They are normally closed circuits, so with the float at rest (down position) the circuit will be closed. Use P20040003 or a standard strap wrench to remove sump. Cleaning Systems Inc. 25 P59000002 Rev:03
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Air Only, Exiting ChemPod: 1. ChemPod is empty. 2. Cracked or loose pick up tube inside ChemPod. 3. ChemPod is empty and not able to fill because air inlet pressure is higher than the pressure from the device filling the ChemPod. 4. Check to make sure that the device that is filling the ChemPod is operating properly. Will Not Fill: 1. ChemPod is in a fault. This is indicated with a flashing red LED. The controller must be reset by removing the 24VAC powering the controller for about 10 seconds. 2. Check to see if you have power to the controller. Check for 24VAC to the controller (at L1 and L2 on the controller) with a voltage meter. 3. Check to make sure that the device that is filling the ChemPod is operating properly. Check the controller output contact. 4. If the ChemPod is being filled by an injection system, check that the injector supplying product to the ChemPod is not clogged. Remove the injector and make sure you can see through the orifice. 5. Not enough pressure on the fill device to overcome the ChemPod operating pressure. 6. ChemPod level switch cannot be operated out of sequence. If so, the controller will time out and have to be reset by removing the 24VAC power supply for about 10 seconds. Sequence of switch: The fluid level switch must call for fill. The lower float (normally closed contact that opens when raised) will activate the fill device and when the upper level switch is satisfied, (upper float is a normally closed contact that opens when raised) it will deactivate the fill device. Overfilling: 1. Product is foaming up inside ChemPod. Verify that air is not getting mixed in from the device filling the ChemPod (i.e. An injector pulling air instead of solution). 2. Inlet valve from external filling device stuck open. 3. Fill device stuck on. 4. Float switch functioning incorrectly. Test switches: Ensure that the floats move freely and both switch contacts are opening when the switch is in the up position and closing in the down position using an Ohm meter or test light. 5. Controller failure. Pressure Fluctuating: 1. Regulator not relieving properly. When the ChemPod is filling, it should be exhausting air out of the exhaust port. Air regulator must be the relieving type for the exhaust valve to operate properly. 2. Exhaust valve not exhausting or leaking all the time. Disassemble, check for debris, and clean the sealing area of the diaphragm. Air Bleeding/Leaking: 1. Safety valve is leaking: a. Operating or system pressure set too high. Note: the safety valve is set to relieve at 75 PSI. 2. Check to see if the air regulator supplying the air is relieving properly. 3. Check to see if air is exhausting at exhaust port during fill up is normal. 4. Leaking steady at exhaust port: a. Dirty or defective diaphragm. Cleaning Systems Inc. 27 P59000002 Rev:03