Blue River Technologies Port-A-Poly Mixer w/2.5 GPH LMI Pump And Secondary Water Dilution Line INSTALLATION AND OPERATION

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1 Blue River Technologies Port-A-Poly Mixer w/2.5 GPH LMI Pump And Secondary Water Dilution Line INSTALLATION AND OPERATION Install your Blue River Technologies Port-A-Poly mixing system in a clean dry area. The system is designed as a portable unit and can sit on any stable and dry platform. The water supply inlet is a 1" Female Pipe Thread connection. Your supply to the system should be able to supply a minimum of 20 gallons per minute of clean filtered water at a line pressure of at least 40 psi. Most city water pressure systems will be capable of supplying a sufficient volume and pressure but be sure that the line that is running from your source to the system is large enough to maintain a constant water pressure during operation of the unit. Blue River Technologies recommends a minimum water supply line of 1" Inside Diameter with a constant water pressure of 50 psi. ( When the system turns on the pressure drop at the discharge point should be from 10 to 20 psi.) Polymer Supply The Blue River Technologies Port-A-Poly mixer can be set up to accept the emulsion polymer from either totes, 55 gallon drums, or 5 gallon pails. Suction tubes for both the 5 and 55 gallon supplies are furnished with your unit. Attach the correct suction tube to the hose with the clamp provided.

2 Tote, Drum or Pail Supply When utilizing the system with a 55 gallon drum or tote supply source, locate the drum or tote as close to the system as possible. It is obviously best to have your tote or drum elevated to provide a flooded suction to the pump. If this is not practical, locating the drum close to the unit will normally be sufficient. Feeding your polymer from the drum (with the drum in a horizontal position) or a tote requires a shutoff valve and suitable strainer at the source and also the drum or tote will need to be vented during operation of the unit. Utilize a feed line of 3/8 or 1/2" I.D. and make sure that it is suitable for suction line. That means the you should use braided hose or semi rigid polyethylene tubing for your supply line. The suction of the pump may collapse non braided pvc tubing. Hook up the supply line to the barb fitting located at the back of the unit. (If the optional calibration column and valve is installed, make sure the valve is in the closed position.) When using the drum in a vertical position or feeding polymer from a 5 gallon pail it is best to use a semi rigid polyethylene, translucent tubing for your feed line. The feed line should go down to near the bottom of the container but make sure that it remains slightly off the bottom to avoid clogging. This line should have an I.D. of at least 3/8". Flow Regulator Your unit includes a water flow regulator on the primary water line. This device will regulate the water flowing thru the primary mixer to a specific flow rate. These valves are available in 5 gpm, 10 gpm, 12 gpm and 15 gpm flow rates. Your unit has been built for a specific flow rate. The flow regulator should be sized to match the mixer nozzle that was shipped with the unit. REGULATOR SOLENOID VALVE FLOWMETER ADJUSTMENT Water Solenoid Valve Your unit includes a water solenoid valve. This valve opens whenever the run switch is activated. When the run switch is returned to the off position this valve will remain open for a short period of time to flush out the line. Inside the control box is a timer relay that can be set from 3 to 60 seconds. This relay will hold your water solenoid valve open after the switch is returned to "OFF" for the number of seconds that is set on the dial. (Factory set at 60 seconds) To change the timer simple rotate the dial to the number of seconds that is desired. Never remove the cover to the control box when the unit is plugged in. Dilution Water Flow Meter The water dilution line is regulated with a 0-20gpm water flow meter. This flow meter is adjusted with the valve located at the bottom of the column. If no secondary water flow is desired this valve should be closed completely. As secondary dilution flow is needed, open up the valve to the desired flow rate. When the run switch is turned on the water solenoid valve will open up. Water will flow thru the primary line at the rate controlled by the water flow regulator. Additional water can be sent to the secondary static mixer by opening up the adjustment valve on the Dilution Water Flow Meter. After making an adjustment to this valve insure that the reading on the pressure gage is at least 10 psi. If it falls below 10 psi you will need more water supply pressure to run the unit at the new setting.

3 Pressure Gage The pressure gage shipped with your unit is a 0-30 psi liquid filled gage. The gage gives the operator a visual indication that the unit is operating normally. Normal operating range is between 10 and 20 psi. Observe the gage during the initial set up and operation of the unit. A substantial change in pressure will indicate insufficient water flow, plugged solution line or other problem with the system. Your flow regulator should keep this pressure in the correct range. If the gage reads low check to insure sufficient line pressure. Mixing Tee and Check Valve Polymer is injected into the mixing tee thru a stainless steel check valve. This check valve insures that water does not back flow into the diaphragm pump during operation. If water would back flow into the polymer line or pump it will cause the polymer to coagulate and plug up the line or pump. If this valve sticks open for any reason the unit must be shut down and the check valve cleaned with mineral oil and inspected to insure that it is operating. Primary Mixing Chamber The Port-A-Poly polymer mixer utilizes a Blue River Technologies Hydro-Mixer as a primary mixing device. This mixer has a nozzle that has holes sized for the desired flow rate. Changes to the nozzle affects the mixing energy of the unit. For example if the holes are enlarged the mixing energy is reduced. As the hole size is reduced or if the flow rate of water thru the mixer is increased the mixing energy increases. If more energy is desired you can increase the size of the flow regulator thus increasing the mixing energy. Likewise a reduction in flow rate will decrease the mixing energy. Blue River Technologies can furnish nozzles with smaller or larger nozzle holes if additional mixing energy is desired.

4 Secondary Water Dilution Line The secondary water dilution line is used to provide additional dilution water to aid in mixing the flocculant with the sludge. Your system is built with the capability of adding an additional 15 gpm of water to the solution. This water is fed into the system behind the primary mixing head and directly in front of the secondary static mixer located on the right hand side of the unit. After the dilution water leaves the top of the dilution water flow meter it flows thru a 1/2 diameter braided pvc line over to the opposite side of the unit. Secondary Static Mixer A secondary static mixer is located on the side of the unit near the discharge port. This mixer is designed to provide a final turbulent mixing zone to cause the dilution water and the flocculant solution to completely emulsify prior to being injected into the sludge line. The inline static mixer should be flushed out at the end of the cycle before the unit is shut down for an extended period. The timer on the control should allow this mixer to be completely flushed out before the water is shut off. If polymer should build up inside this mixer you should be able to see it thru the clear pvc chamber. Flush the system with clean water to clean out the mixer. Secondary Static Mixer Check Valve Water Dilution Line Check Valve A check valve is installed in front of the Secondary Static Mixer to prevent polymer solution from flowing back into the secondary water dilution line and flow meter. This ball type check valve is easily taken apart and cleaned if necessary. Unscrew the unions located at the top and bottom of the check valve. Remove the center section and clean the ball and seat area with a clean dry rag. Reinstall the valve with the flow direction arrow pointing up.

5 Diaphragm Pump Operation Your unit includes a high viscosity diaphragm metering pump. This unit is fully described in the pump manual section of this booklet. You should read through this section prior to operation of your unit. The pump includes two ways to adjust the output of the pump. Stroke Length Adjustment: The stroke adjustment knob located on the front of the pump changes the output of each stroke of the pump. This adjustment should never be turned below the 10% set point. This adjustment should always be made with the pump running. Frequency Adjustment: The frequency adjustment is done from the front of the panel. The LMI B921-85H pump has a maximum output of 2.5 gallons per hour. To reduce or increase the output of the pump with the stroke frequency adjustment use the arrow keys on the right side of the control panel to adjust the stroke frequency up or down. This adjustment will change the stroke rate from a low of 0 to a high of 100 strokes per minute. This will alter the output of the pump from 0 to a maximum of 2.5 gallons per hour depending on the position of the Stroke length adjustment dial. Remote Speed Adjustment Your pump may include a 4-20 ma speed adjustment option. Consult the manual on how to install and operate this option.

6 Primer Port A primer port and valve is included directly above the pump. A 60mL syringe was included with your Port-A- Poly mixer. After hooking up the polymer supply you will need to assist the pump to pull up the high viscosity emulsion polymer up through the feed lines and into the pumping chamber for the start up of the pump. (This is also required should you let your pump run dry during normal operation) A plastic drip cover is included with the unit. Leave this drip cover over the pump at all times except when changing the frequency of the pump. To use the primer port, remove the cap from the valve. Remove the cover from the syringe tip and place the tip into the opening of the primer valve. Open the valve by turning the lever and draw out on the syringe. Close the valve and return the syringe plunger to the full closed position, open the valve and repeat the process until you can draw a small amount of polymer into the syringe. You will hear the pump change tone as it draws chemical into the diaphragm chamber. You may need to repeat this process to expel all of the air out of your polymer supply line. This is normal when setting up a new drum or container of polymer. You can minimize the requirement for priming the unit by keeping lines full during the switching out of containers of polymer. Optional Calibration Column An optional calibration column is available for the Blue River Technologies Port-A-Poly unit. This column includes a ball valves and fittings and can be installed in the pump suction port located at the back of the pump. This column can be used to precisely set the output of the pump to a desired flow rate. The column is marked for a timed rate of 1 minute. To calibrate your pump, fill the column with chemical up to the high level mark "0". Make sure the valve located at the back of the Port-A-Poly (the supply line valve) is closed. Turn the pump on and run the pump for a period of 1 minute. Observe the reading on the right side of the column.

7 Initial Startup Port A Poly is plumbed up to a 1 water supply line that can maintain a minimum of 40psi water pressure with 30 gpm flowrate. Unit should be wired into a 110VAC 1ph electrical outlet with Ground Fault Protection. 1. Turn on Power with the OFF ON Switch located on the left hand side of the control box. Red LED should illuminate. 2. Insure that the water supply line valve is in the on position. 3. Insure that the secondary dilution line valve is in the closed position. 4. Turn on the unit with the Run switch located on the right hand side of the control box. Green LED should illuminate, water valve should open and water will begin to flow thru the primary mixer. The LMI pump should turn on begin to pump polymer. (If you do not want to prime the pump or pump polymer at this time, push the start/stop button located on the right hand side of the pump face.) 5. For initial start up or if you have changed out your polymer supply you may need to prime the LMI Diaphram pump. Use the primer port located above the pump and the plastic syringe furnished with your unit to prime the LMI pump. ( If you turned off the LMI you will need to restart the pump with the start/stop button located on the right hand side of the pump face. 6. After priming the pump adjust the stroke length to the desired setting by turning the adjustment knob up or down. 7. Adjust the stroke frequency to the desired setting by using the up or down arrow keys located on the pump face. 8. If a secondary water dilution is to be used, open up the water dilution valve located at the bottom of the flow meter. Observe the pressure reading on the pressure gage. It should not fall below 10psi after the correct gpm on the water dilution line is set. 9. At the completion of the run cycle turn the unit off with the Run switch. The LMI pump will shut off, the water will continue to run for 60 seconds to flush out the line. (If you anticipate using the unit again in a short period of time you can turn off the unit with the On Off switch and the purge cycle will not take place.