Instruction Manual ADVANCE TM Wall Panel Gas Feeders Series WP70CV3

Transcription

1 LIQUID FIL DO NOT TAM Instruction Manual ADVANCE TM Wall Panel Gas Feeders Series WP70CV3 LIQUID FIL DO NOT TAM 500 PPD (10 kg/h Chlorine & Sulfur Dioxide 3000 PPD (60 kg/h Chlorine & Sulfur Dioxide Auto Control Valve with Switches 500 PPD (10 kg/h Maximum Auto Control Valve with Switches 3000 PPD (60 kg/h

2 These instructions describe the installation, operation and maintenance of the subject equipment. Failure to strictly follow these instructions can lead to an equipment rupture that may cause signifi cant property damage, severe personal injury and even death. If you do not understand these instructions, please call De Nora Water Technologies (DNWT, Inc. for clarifi cation before commencing any work at and ask for a Field Service Manager. De Nora Water Technologies, Inc. reserves the rights to make engineering refinements that may not be described herein. It is the responsibility of the installer to contact DNWT Inc. for information that cannot be answered specifically by these instructions. Any customer request to alter or reduce the design safeguards incorporated into DNWT Inc. equipment is conditioned on the customer absolving DNWT Inc. from any consequences of such a decision. DNWT Inc. has developed the recommended installation, operating and maintenance procedures with careful attention to safety. In addition to instruction/operating manuals, all instructions given on labels or attached tags should be followed. Regardless of these efforts, it is not possible to eliminate all hazards from the equipment or foresee every possible hazard that may occur. It is the responsibility of the installer to ensure that the recommended installation instructions are followed. It is the responsibility of the user to ensure that the recommended operating and maintenance instructions are followed. De Nora Water Technologies, Inc. cannot be responsible for deviations from the recommended instructions that may result in a hazardous or unsafe condition. DNWT Inc. cannot be responsible for the overall system design of which our equipment may be an integral part of or any unauthorized modifi cations to the equipment made by any party other that DNWT Inc. DNWT Inc. takes all reasonable precautions in packaging the equipment to prevent shipping damage. Carefully inspect each item and report damages immediately to the shipping agent involved for equipment shipped F.O.B. Colmar or to DNWT Inc. for equipment shipped F.O.B Jobsite. Do not install damaged equipment. De Nora Water Technologies, COLMAR OPERATIONS COLMAR, PENNSYLVANIA, USA IS ISO 9001: 2008 CERTIFIED USE ONLY IN ACCORDANCE WITH INSTRUCTION MANUAL WARNING: HAZARDOUS VOLTAGES PROTECTIVE GROUND (EARTH TERMINAL WARNING: WARNING, AS USED IN THIS MANUAL, IS DEFINED AS A CONDITION OR PRACTICE WHICH COULD RESULT IN PERSONAL INJURY OR LOSS OF LIFE. CAUTION: CAUTION, AS USED IN THIS MANUAL, IS DEFINED AS A CONDITION OR PRACTICE WHICH COULD RESULT IN DAMAGE TO OR DESTRUCTION OF THE EQUIPMENT OR APPARATUS UNDER TEST

3 SAFETY The recommended operating procedures have been designed with careful attention to safety. De Nora Water Technologies, Inc. has made formal safety reviews of the initial design and any subsequent changes. This procedure is followed for all new products and covers areas in addition to those included in applicable safety standards. Regardless of these efforts, it is not possible to eliminate all hazards from the test equipment or to foresee every possible hazard that may occur. It is therefore essential that the user, in addition to following the safety rules in this manual, also carefully consider all safety aspects of the test before proceeding. Safety is the responsibility of the user. This equipment has been designed in accordance with safety specifi cations IEC and ANSI/ISA S82.01 and meets the requirements for Class I, Installation Category III equipment. Observe the following safety precautions: Observe all safety warnings marked on the equipment. These warnings identify areas of immediate hazard which could result in personal injury or loss of life. Do not use this equipment for any purpose other than described in this manual. Disconnect power to the WP70CV3 prior to making any terminal connections within the actuator or vacuum switch enclosures. Do not operate the equipment with the protective covers removed. Operation without the protective covers presents an electric shock hazard. Use all practical safety precautions to prevent contact with energized parts of the equipment and related circuits. The control valve contained within the WP70CV3 Gas Feeders operate from a single-phase power source. The voltage to ground from the power source must not exceed the maximum rated operating voltage, 250 Vac. Before making connection to the power source, determine that the voltage of the power source is correct. The power source must have a high rupture fuse or circuit breaker rated no higher than 15 A. Capital Controls recommends that qualifi ed personnel install and connect the equipment. Component replacement and internal adjustments must be made by qualifi ed service personnel only

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5 Table Of Contents SAFETY INTRODUCTION Reference Data COMPONENT DESCRIPTION Wall Panel Vacuum Regulator Automatic Valve/Controller Gas Flowmeter Vacuum Switches Ejector or CHLOR-A-VAC PRINCIPLE OF OPERATION INSTALLATION Gas Feeder Wall Panel Vacuum Regulator Ejector/CHLOR-A-VAC Vacuum Lines Automatic Valve/Controller OPERATION Start Up Capacity Conversion Calibration SERVICE TROUBLESHOOTING CHART FIGURES 1 Gas Feed System

6 1 INTRODUCTION This manual describes Series WP70CV3 Wall Panel Gas Feeders with Automatic Control. Component instruction manuals and supplemental data are referenced where applicable. The abbreviated model number describes the basic design: WP70CV PPD (4 kg/h Maximum WP70CV PPD (10 kg/h Maximum WP70CV PPD (60 kg/h Maximum POSITION FEATURE DESCRIPTION A Power Requirements 1 110/250 VAC; 47/66 Hz B Gas Feeder 1 5 point calibration to factory standard Flow Meter C Design Level A Design Level D Feed Capacity & Gas AC 5 PPD (100 g/h Cl 2 AS 5 PPD (100 g/h SO 2 BA 5 PPD, NH 3 BC 10 PPD, (200 g/h - Cl 2 BS 10 PPD, (200 g/h - SO 2 CA 10 PPD, (200 g/h - NH 3 CB PPD, (375 g/h - CO 2 CC 25 PPD, (500 g/h - Cl 2 CS 25 PPD, (500 g/h - SO 2 (18.75 PPD, 375 g/h CO 2 DA 25 PPD, (500 g/h - NH 3 DB 37.5 PPD, (750 g/h - CO 2 DC 50 PPD, (1 kg/h - Cl 2 DS 50 PPD, (1 kg/h - SO 2 (3.75 PPD, 750 g/h CO 2 FA 50 PPD, (1 kg/h - NH 3 FB 75 PPD, (1.5 kg/h - CO 2 These ranges overlap for FC 100 PPD, (2 kg/h - Cl 2 the Models WP70CV32 FS 100 PPD, (2 kg/h - SO 2 (75 PPD, 1.5 kg/h CO 2 and WP70CV33 GA 100 PPD, (2 kg/h - NH 3 GB 150 ppd, (3 kg/h - CO 2 GC 200 PPD, (4 kg/h - Cl 2 GS 200 PPD, (4 kg/h - SO 2 (150 PPD, 3 kg/h CO 2 HB 225 PPD, (4.5 kg/h - CO 2 HC 300 PPD, (6 kg/h - Cl 2 HS 300 PPD, (6 kg/h - SO 2 (225 PPD, 4.5 kg/h CO 2 JA 250 PPD, (5 kg/h - NH 3 JB 750 PPD, (15 kg/h - CO 2 JC 500 PPD, (10 kg/h - Cl 2 JS 500 PPD, (10 kg/h - SO 2 (375 PPD, 7.5 kg/h CO 2 TA 500 PPD, (10 kg/h - NH 3 TB 750 PPD, (15 kg/h - CO 2 TC 1000 PPD, (20 kg/h - Cl 2 TS 1000 PPD, (20 kg/h - SO 2 (75 PPD, 15 kg/h CO 2 UA 1000 PPD, (20 kg/h - NH 3 UB 1500 PPD, (30 kg/h - CO 2 UC 2000 PPD, (40 kg/h - Cl 2 US 2000 PPD, (40 kg/h - SO 2 (1500 PPD, 30 kg/h CO 2 VB 2250 PPD, (45 kg/h - CO 2 VC 3000 PPD, (60 kg/h - Cl 2 E Vacuum Switches 0 Vacuum Switches not required 1 With High & Low Cl 2 /SO 2 Vacuum Switches 2 With High & Low NH 3 Vacuum Switches A FEATURE A B C D E POSITION

7 1.1 Reference Data Throughout this manual, the following literature is referenced. This list is a guide for additional literature which may be required before installation and start-up of the Series WP70CV3 feeder Vacuum Regulators Instruction Manuals: Direct cylinder ton container mounted Series NXT3000 Cylinder, Ton Container, or Wall Mounted Vacuum Regulator Automatic Switchover Instruction Manual: Control Valve Instruction Manual: Ejectors: Standard O-ring Diaframless Valve Seat EJ17: High Capacity , 2 Inch or 3 Inch Wall Panel Dimensions: without vacuum switches PPD (4 kg/h, 100D PPD (10 kg/h, 100D PPD (20-40 kg/h, 100D PPD (60 kg/h, 100D1055 with vacuum switches PPD (4 kg/h, 100D PPD (10 kg/h, 100D PPD (20-40 kg/h, 100D PPD (60 kg/h, 100D Wiring Diagram: without vacuum switches with vacuum switches High and low Vacuum Switches Instruction Manual: Voltage: Vac, Hz Power: 38.5 VA

8 2 COMPONENT DESCRIPTION 2.1 Wall Panel Gas feeder wall panels are factory assembled, pre-piped and shipped as a unit ready for mounting and mating with utility connections. 2.2 Vacuum Regulator Vacuum regulators are used to meter the gas being dispensed. The vacuum regulator may be direct cylinder mounted, direct ton container mounted, or manifold mounted. Automatic switchover provides a continuous gas feed system. 2.3 Automatic Valve/Controller The automatic valve opens or closes in response to signals received from a fl ow transmitter and/or a residual analyzer. Manual and automatic valve positioning is described in Bulletin The controller provides a characterized electrical valve position signal (4-20 madc gas fl ow transmission for the purpose of indicating and/or recording gas fl ow. The automatic valve may be manually operated either from the integral push buttons or in the case of power loss by using the manual knob. The controller requires connection of electrical power and signal input(s. It is the users responsibility to provide appropriate protection (circuit breakers from overload conditions. Refer to Bulletin Gas Flowmeter The gas flowmeter provides a visual indication of the gas flow rate. The capacity range of each flowmeter is indicated on the fl owmeter tube and is matched to the automatic valve. 2.5 Vacuum Switches The optional vacuum switches are furnished in a NEMA 4X enclosure, loose for fi eld mounting for the Series WP70CV3. The vacuum switches are internally mounted and wired on the Series WP70CV3VS. Refer to Ejector or CHLOR-A-VAC The vacuum producing device provided with the system can be either an ejector or a chemical induction unit (CHLOR-A-VAC. Both devices produce vacuum at the level required to operate the vacuum feed system Ejector/Check Valve The ejector/check valve is operated by the fl ow of water under suffi cient pressure and velocity to create the vacuum necessary to operate the vacuum regulator. In most instances, a booster pump is required to provide the necessary pressure and fl ow rate. The ejector/check valve assembly is remote mounted. Refer to CHLOR-A-VAC CHLOR-A-VAC units produce a vacuum when process water passes through water inlet ports and through a venturi. The high vacuum and recessed impeller create great turbulence and complete chemical mixing. The CHLOR-A-VAC is remote mounted at the point of application. Refer to ,

9 3 PRINCIPLE OF OPERATION When the ejector or CHLOR-A-VAC is operating, gas enters the vacuum regulator, being reduced from a positive pressure to a constantly regulated vacuum by the throttling action of the inlet valve. The gas then passes through the vacuum regulator, fl owmeter, the automatic valve and into the ejector or CHLOR-A-VAC. Within the ejector or CHLOR-A-VAC, the gas is thoroughly mixed with water or process liquid to form a chemical solution which is delivered to the point(s of application. Refer to Figure 1. Figure 1 - Gas Feed System

10 4 INSTALLATION 4.1 Gas Feeder Wall Panel Locate the gas feeder wall panel where it can be isolated to prevent tampering by unauthorized personnel. Wall panel location should permit easy access for inspection and maintenance, ventilation, and ease of observation by operating personnel. Vacuum line connections are provided for remote mounted vacuum regulator and ejector or CHLOR-A-VAC. Electrical connections are made to the wall panel mounted valve/controller. Refer to reference drawings for dimensions and utility connection locations Wall Panel Mounting Each wall panel is furnished with four (4 1/2" diameter holes designed for use with 5/16" (minimum diameter anchor bolts. Refer to the dimensional drawings for location of holes Wall Panel Wiring See wiring diagram or with vacuum switches. 4.2 Vacuum Regulator Refer to the appropriate vacuum regulator instruction manual. 4.3 Ejector/CHLOR-A-VAC Ejector Refer to the vacuum regulator instruction manual for ejector installation, and ejector instruction manual for maintenance and service requirements CHLOR-A-VAC Refer to the appropriate instruction manual for installation, maintenance and service requirements. 4.4 Vacuum Line(s Refer to for vacuum line size requirements. Vacuum lines should be made of polyethylene, PVC, or similar materials suitable for moist gas service. 4.5 Automatic Valve/Controller Refer to Instruction Manual

11 5 OPERATION This section covers operating practices applicable to the wall panel gas feeder. Refer to the applicable manuals for individual components. 5.1 Start-up Refer to the Start-Up Section of the Vacuum Regulator Instruction Manual, then proceed to the control valve instruction manual, for set up to the process parameters. After the process parameters are set, operate the valve in manual to verify that the gas is feeding correctly with process water fl owing through the ejector. After the system operation integrity has been verified, the control valve may now be placed in automatic in the chosen control mode. 5.2 Capacity Conversion Each gas dispensing system is designed to provide the gas fl ow requirements to the point (s of application. The limit of the gas fl ow is indicated by the calibrated scale on the gas fl owmeter. Should the gas fl ow requirements change to exceed the indicated value, it will usually be possible to achieve the new requirements by substituting re-sized parts provided that the new requirements are within the maximum capacity of the vacuum regulator and ejector. Since a number of factors must be considered, consult the supplier or the factory to determine the modifi cations required. The components that may require modifi cation are: Vacuum Regulator Valve Head Gas Flowmeter Ejector Interconnecting Vacuum Lines 5.3 Calibration The automatic control valve is set at the factory with a 5 point characterization. The valve may be characterized up to 11 points or recharacterized after component changes. Refer to Instruction Bulletin

12 6 SERVICE NOTE: DUE TO THE NATURE OF THE EQUIPMENT AND THE USE OF CUSTOM-BUILT ELEMENTS, IT IS RECOMMENDED THAT THE EQUIPMENT BE RETURNED TO THE FACTORY FOR REPAIR OR REPLACEMENT IF FOUND TO BE DEFECTIVE IN FORM OR FUNCTION. THIS EQUIPMENT IS ONLY SERVICEABLE BY QUALIFIED PERSONNEL. NOTE: BEFORE SERVICING, EVACUATE ALL THE GAS FROM THE SYSTEM. REFER TO THE APPLICABLE VACUUM REGULATOR INSTRUCTION MANUAL

13 7 TROUBLESHOOTING CHART TROUBLE PROBABLE CAUSE CORRECTIVE ACTION 1. Required gas flow not achieved at start-up. 2. Required gas fl ow rate is not achieved on start-up following an extended period of shutdown. 3. Flowmeter fl oat observed bouncing and/or maximum gas fl ow cannot be achieved during normal operation. 4. Maximum gas fl ow fails to provide desired level of chemical residual at point of sampling. 5. Minimum gas fl ow provides too high a level of chemical residual at point of sampling. 6. After an operational period, the gas fl ow read ing on the valve indicator does not agree with the rate meter indication. 7. Flowmeter fails to indicate gas fl ow during normal operation but there is no out-of-gas indication. 8. Unstable chemical residual a. Insuffi cient ejector vacuum caused by insuffi cient water supply pressure or excessive back pressure. b. Leakage at vacuum line connection at outlet from fl owmeter, fate control valve, differential from fl owmeter, differential pressure regulator, and/or inlet to ejector. c. Vacuum line(s if fl exible, crimped. d. Length of vacuum line(s exceeds maximum allowable transport distance. a. Insuffi cient ejector vacuum. b. Leakage at vacuum line connection at outlet of fl owmeter, rate control valve or inlet to ejector. c. Vacuum line(s, if fl exible, crimped. d. Leakage around flowmeter gaskets. a. Gas inlet fi lter of vacuum regulator dirty. b. Rate valve dirty. c. Flowmeter dirty. d. Ejector water supply pressure fluctuating too wide (fl oat bounce. Insuffi cient ejector vacuum. a. Air leakage upstream of fl owmeter. b. Chemical demand and/or water fl ow has increased above original design capacity. a. Chemical demand and/or fl ow of water has decreased below original design capacity. Dirt deposits on the valve plug or a scored valve seat caused by less than a pure gas supply. a. Rate valve plugged. b. Automatic valve closed. c. Gas fl owmeter plugged. d. Vacuum lines, if fl exiible, crimped. e. Loss of vacuum downstream of fl owmeter. a. Oversized system. b. Improperly tuned controller. a. Refer to Trouble 9. b. Inspect each connection and remake if necessary. c. Replace vacuum tubing and arrange line(s to eliminate crimping. d. Refer to Bulletin a. Refer to Trouble 8. b. Inspect each connection and remake if necessary. c. Replace vacuum tubing and arrange line(s to eliminate crimping. d. Inspect and align fl owmeter or replace gaskets. a. Replace gas inlet fi lter assembly. b. Clean rate valve. c. Clean fl owmeter. d. Correct water supply pressure as necessary. a. Refer to Troubles 1 and 2. b. Contact supplier and review equipment requirements. a. Contact your supplier and review equipment requirements. Refer to the maintenance section for cleaning procedure. Examine the plug and seat. If damage is evident after cleaning, replace the valve plug and/or seat and recharacterize the valve. a. Clean rate valve. b. Refer to Trouble 18. c. Clean gas fl owmeter. d. Replace vacuum tubing and arrange lines to eliminate crimping. e. Refer to Troubles 1 and 2. a. Consult factory for re-sizing. b. See Control Valve Instruction Manual, Tuning Section

14 7 TROUBLESHOOTING CHART CONTINUED TROUBLE PROBABLE CAUSE CORRECTIVE ACTION 9. Insuffi cient ejector vacuum a. Y-strainer in water supply line is dirty reducing available supply pressure. b. Back pressure is greater than value listed for one of the following reasons: a solution valve, if present, not fully open b solution line, if present, partially blocked c back pressure at point of application has increased above its original value. c. Ejector nozzle and/or throat dirty. a. Clean Y-strainer and refer to ejector instructions. b. Open solution valve, clean solution line, determine cause of abnormally high back pressure and take steps to correct. c. Clean nozzle and/or throat. 10. Gas leak a. Gas leak at container valve or isolating valve packing. b. Leak at lead gasket. c. Leak across gas inlet valve seat causes gas to leak from vent line. 11. Loss of gas feed a. Dirty or plugged ejector nozzle. b. Insuffi cient water pressure to operate ejector. c. No gas supply. a. Tighten container valve packing nut without excessive force. If this does not eliminate the leak, close the valve and call the gas supplier. b. Replace gasket. c. Clean inlet valve seat. a. Check for vacuum in ejector. Clean nozzle. b. Provide proper water pressure. c. Replenish gas supply. 12.Flooded feeder a. Dirt lodged on the ejector check valve seat. a. Clean or replace seat or O-ring. 13. Erratic operation a. Oversized system. a. Consult factory for re-sizing. 14. Runaway valve a. Faulty feedback potentiometer. b. Improperly tuned controller. a. Replace/rewire feedback potentiometer. b. See Control Valve Instruction Manual, Tuning Section. 15. Automatic valve neither opens or closes a. No power. b. Fuse blown or circuit breaker tripped. c. Incorrect or loose wiring. d. Gear train binding. e. Incorrect power. f. Faulty printed circuit board in Controller. g. Faulty valve motor. a. Check power switch is ON. b. Replace blown fuse or reset circuit breaker. c. Check all wiring. d. Remove valve cover, with power OFF, manually turn gear train on valve checking for ease of rotation. e. Check for proper voltage on terminals. Check Controller line voltage switch. f. Refer to Control Valve Instruction Manual. g. Refer to Control Valve Instruction Manual. Design improvements may be made without notice. Represented by: De Nora Water Technologies 3000 Advance Lane Colmar, PA ph fax web: mail: info.dnwt@denora.com SEP Registered Trademark All Rights Reserved.