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USFilter V-2000 Manual

Chlorinator
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SERIES V-2000
CHLORINATOR
3000 LB/24 HR
AUTOMATIC CONTROL
BOOK NO. IM 25.055AC UA
ISSUE C

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  • Page 1 SERIES V-2000 CHLORINATOR 3000 LB/24 HR AUTOMATIC CONTROL BOOK NO. IM 25.055AC UA ISSUE C...

  • Page 2: Ordering Information

    AUTOMATIC CHLORINATOR - 3000LB/24HR EQUIPMENT SERIAL NO. _________________ DATE OF START-UP _____________________ START-UP BY ___________________________ Prompt service available from nationwide authorized service contractors. ORDERING INFORMATION In order for us to fill your order immediately and correctly, please order material by description and part number, as shown in this book.
  • Page 3 This instruction book provides installation, operation, and maintenance instructions for the USFilter's Wallace & Tiernan Products (USF/W&T) Series V-2000 (Chlorine) Gas Feeder (control module and injector). Of necessity, more information is provided than applies to each specific instal- lation; disregard those details that do not apply to your installation.
  • Page 4 AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: When ordering material always specify model and serial number of apparatus. Table Of Contents Very Important Safety Precautions ......1.010-40,-41 Preventive Maintenance General Information ... 1.010-5 Maintenance Record Card ........1.010-13 Regional Offices ............1.010-1 Technical Data ............
  • Page 5 AUTOMATIC CHLORINATOR - 3000LB/24HR VERY IMPORTANT SAFETY PRECAUTIONS - CHLORINE This and the following pages titled “Very Important Safety Precautions” provide, in brief, information of urgent importance relative to safety in the installation, operation, and maintenance of this equipment. WARNING TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE, OBSERVE THE FOLLOWING: THIS EQUIPMENT SHOULD BE INSTALLED, OPERATED, AND SERVICE ONLY BY TRAINED,...
  • Page 6 DO NOT DISCARD THIS INSTRUCTION BOOK UPON COMPLETION OF INSTALLATION. INFORMATION PROVIDED IS ESSENTIAL TO PROPER AND SAFE OPERATION AND MAIN- TENANCE. ADDITIONAL OR REPLACEMENT COPIES OF THIS BOOK ARE AVAILABLE FROM: USFILTER'S WALLACE & TIERNAN PRODUCTS 1901 WEST GARDEN ROAD VINELAND, NEW JERSEY 08360 PHONE: (856) 507-9000...
  • Page 7 Preventive maintenance kits may be ordered directly from the company that supplied your equip- ment, or they may be ordered directly from USFilter’s Wallace & Tiernan Products. For ordering numbers, refer to the parts list at the rear of this book.
  • Page 8 AUTOMATIC CHLORINATOR - 3000LB/24HR PREVENTIVE MAINTENANCE SCHEDULE AND RECORD OF PERFORMANCE This equipment should receive preventive maintenance on a one (1) year cycle.* It is recommended that the following table be used to plan, schedule, and record this important work. a l l *NOTE: This is the recommended cycle.
  • Page 9 Direct any questions concerning this equipment that are not answered in the instruction book to the Reseller from whom the equipment was purchased. If the equipment was purchased directly from USFilter's Wallace & Tiernan Products (USF/W&T), contact the office indicated below.
  • Page 10 AUTOMATIC CHLORINATOR - 3000LB/24HR IM 25.055AC UA (C/6-01)
  • Page 11 AUTOMATIC CHLORINATOR - 3000LB/24HR SECTION 1 - TECHNICAL DATA List Of Contents PARA./DWG. NO. Technical Data ............1.1 Illustrations Performance V-2000 Injector Inlet Pressure Limits....25.055.190.010 Vacuum Line Length Limits ....... 25.052.190.030 IM 25.055AC UA (C/6-01)

  • Page 12: Technical Data

    AUTOMATIC CHLORINATOR - 3000LB/24HR Technical Data y t i t n i c i l i t a h t i o i t h t i i t u i n i t e l j n i - i t j n i .
  • Page 13 AUTOMATIC CHLORINATOR - 3000LB/24HR V-2000 INJECTOR INLET PRESSURE LIMITS - PERFORMANCE 25.055.190.010 ISSUE 1 5-97 IM 25.055AC UA (C/6-01)
  • Page 14 AUTOMATIC CHLORINATOR - 3000LB/24HR VACUUM LINE LENGTH LIMITS - PERFORMANCE Used In Remote Vacuum Gas Feeders 25.052.190.030 ISSUE 2 10-84 IM 25.055AC UA (C/6-01)

  • Page 15: Table Of Contents

    Operation ............... 2.16 Illustrations Typical Installation Series V-2000 Gas Feeder ........25.055.110.035 Series V-2000 Gas Feeder - With 2" Injector ..25.055.110.070 2" Injector With 3/4" Ball Valve ......25.055.110.075 Installation Piping 2" Injector - Connections for Prime and Flush Operations ............

  • Page 16: Location Of Components

    AUTOMATIC CHLORINATOR - 3000LB/24HR WARNING: THIS CONTROL MODULE IS DESIGNED TO OP- ERATE UNDER VACUUM ONLY. TO AVOID POSSIBLE SE- VERE PERSONAL INJURY OR EQUIPMENT DAMAGE, DO NOT CONNECT TO A SOURCE OF GAS UNDER PRESSURE. Location of Components The general physical requirements of the installation are shown on the Typical Installation drawings.
  • Page 17 AUTOMATIC CHLORINATOR - 3000LB/24HR Rotameter For protection in shipment, the rotameter and associated parts are re- moved after the gas feeder is factory tested. These parts are separately packaged; assemble and install as indicated on Dwg. 25.055.151.010. Vent As shown on the typical installation drawings, a vent line is required from the pressure relief port to a point outside the building where the gas cannot cause injury to personnel or damage to equipment.
  • Page 18 AUTOMATIC CHLORINATOR - 3000LB/24HR suspected, inspect the O-rings and replace them if there is any doubt about their condition. Injector Suction Connection Except in those instances where the injector is installed in the control module, a line must be provided to carry the gas from the module to the injector.
  • Page 19 AUTOMATIC CHLORINATOR - 3000LB/24HR For the two-inch variable throat injectors, two-inch polyethylene pipe or two-inch rigid PVC pipe is normally used. Solution hose may be connected directly to the injector tailway. If rigid PVC pipe is used, a piece of straight pipe at least 12 inches long should be coupled to the end of the injector tailway before any elbows, tees, or Saunders valves are used.
  • Page 20 AUTOMATIC CHLORINATOR - 3000LB/24HR installed that will not give more than five inches of water differential between the module and vacuum regulator at the maximum chlori- nator feed rate. Note that the equivalent length of the fittings must be added to the tubing length to obtain the total equivalent length as shown on the graph.
  • Page 21 AUTOMATIC CHLORINATOR - 3000LB/24HR SERIES V-2000 GAS FEEDER - TYPICAL INSTALLATION 25.055.110.035 ISSUE 2 6-97 IM 25.055AC UA (C/6-01)
  • Page 22 AUTOMATIC CHLORINATOR - 3000LB/24HR SERIES V-2000 GAS FEEDER - TYPICAL INSTALLATION With 2" Injector 25.055.110.070 ISSUE 2 02-00 IM 25.055AC UA (C/6-01)
  • Page 23 AUTOMATIC CHLORINATOR - 3000LB/24HR 2" INJECTOR WITH 3/4" BALL VALVE - TYPICAL INSTALLATION 25.055.110.075 ISSUE 0 4-87 IM 25.055AC UA (C/6-01)
  • Page 24 AUTOMATIC CHLORINATOR - 3000LB/24HR 2" INJECTOR - INSTALLATION PIPING Connections for Prime and Flush Operation 25.100.006.122 ISSUE 4 8-93 IM 25.055AC UA (C/6-01)
  • Page 25 AUTOMATIC CHLORINATOR - 3000LB/24HR 2" INJECTOR - INSTALLATION PIPING Connections for Manual Suction Shut-Off Unit 25.100.06.131 ISSUE 3 1-90 IM 25.055AC UA (C/6-01)
  • Page 26 AUTOMATIC CHLORINATOR - 3000LB/24HR 2" INJECTOR - INSTALLATION PIPING Connections for Intermittent Start-Stop Operation 25.100.006.142 ISSUE 2 4-93 IM 25.055AC UA (C/6-01)
  • Page 27 AUTOMATIC CHLORINATOR - 3000LB/24HR 2" INJECTOR - INSTALLATION PIPING Connections for Intermittent Start-Stop Operation With Injector Suction Shut-Off Unit 25.100.006.152 ISSUE 2 8-92 IM 25.055AC UA (C/6-01)
  • Page 28 AUTOMATIC CHLORINATOR - 3000LB/24HR TEMPERATURE AND PRESSURE: PVC PIPE IS NOT RECOMMENDED FOR TEMPERATURES OVER 130°F OR BELOW 0°F, NOR FOR LINES THAT MAY BE EXPOSED TO PHYSICAL ABUSE (SEE MANUFACTURER’S RECOMMEN- DATIONS). ONE HUNDRED FEET OF PIPE WILL EXPAND OR CONTRACT APPROXIMATELY 0.7 INCHES FOR EVERY 10°F TEMPERATURE CHANGE.
  • Page 29 2" Injector Prime and Flush Operation ....3.3.3 Illustrations Flow Diagram Series V-2000 Gas Feeder ........25.055.181.010 2" Injector - Manually Operated ......25.100.181.011 2" Injector - Intermittent Start-Stop Operation .. 25.100.181.021 2" Injector - Prime & Flush Operation ....25.100.181.031 Operation - Instructions for Manual Operation ..

  • Page 30: Gas Supply

    AUTOMATIC CHLORINATOR - 3000LB/24HR Preparation for Operation WARNING: HAZARDOUS GAS IS PRESENT IN THIS EQUIP- MENT DURING NORMAL OPERATION. TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR DAMAGE TO THE EQUIP- MENT, READ THIS INSTRUCTION BOOK AND THE APPRO- PRIATE GAS MANUAL BEFORE CONNECTING THIS EQUIP- MENT TO A SUPPLY OF GAS.
  • Page 31 AUTOMATIC CHLORINATOR - 3000LB/24HR (2) At any tubing connector or pipe fitting in the gas supply line. This may be corrected by tightening the connector or fitting, or by replacing any defective connector O-ring. f. Check the following to be sure all connections are tight: (1) The V-notch extension chamber through which the V-notch plug travels.
  • Page 32 AUTOMATIC CHLORINATOR - 3000LB/24HR 3.2.2 Stopping - For Short Periods Turn off the injector water supply. (For two-inch injector, turn off the injector shut-off valve.) 3.2.3 Stopping - For Extended Periods a. Turn off the gas supply at each supply container valve. b.
  • Page 33 AUTOMATIC CHLORINATOR - 3000LB/24HR the pump is off. In this manner, the gas feeder is prevented from delivering gas to the point of application unless the pump is operating. 3.2.6 Preparation for Winter Shut-Down If the gas feeder is to be shut down for an extended period during freezing weather, the following procedure must be followed: a.
  • Page 34 AUTOMATIC CHLORINATOR - 3000LB/24HR notch variable orifice. Thus the flow through the orifice is entirely a func- tion of the size of the orifice as determined by the position of the V-notch plug as set by a positioner in response to an external electric signal. Gas under pressure enters the vacuum regulator.
  • Page 35 AUTOMATIC CHLORINATOR - 3000LB/24HR force of the spring (K) through the diaphragm (L) and the attached linkage, exerts a pull on the diaphragm (G) and holds the seat (H) closed. When the three-way valve is in the ON position, pressure from the chamber (C) is transmitted to the diaphragm (L) and the injector operates as described above.

  • Page 36: Pressure Relief Valve

    AUTOMATIC CHLORINATOR - 3000LB/24HR V-NOTCH VARIABLE ORIFICE VACUUM DIFFERENTIAL REGULATING VALVE 26" TO 58" WATER VACUUM 14" TO 42" WATER VACUUM ROTAMETER VACUUM SUPPLY GAUGE 13" TO 48" WATER VACUUM MANUAL FEED INJECTOR VACUUM GAUGE RATE ADJUSTER 6" MERCURY MINIMUM (6.5" MERCURY MINIMUM FOR FEED RATES ABOVE 2000 LBS CHLORINE PER 24HRS OR EQUIVALENT FOR...
  • Page 37 AUTOMATIC CHLORINATOR - 3000LB/24HR FOR APPLICATION AGAINST PRESSURE 2" INJECTOR - FLOW DIAGRAM Manually Operated WITH SUCTION SHUT-OFF UNIT 25.100.181.011 FOR APPLICATIONS NEGATIVE HEAD ISSUE 4 5-97 IM 25.055AC UA (C/6-01)
  • Page 38 AUTOMATIC CHLORINATOR - 3000LB/24HR FOR APPLICATION AGAINST PRESSURE FOR APPLICATION AGAINST PRESSURE FOR APPLICATION AGAINST PRESSURE FOR APPLICATION AGAINST PRESSURE 2" INJECTOR - FLOW DIAGRAM Intermittent Start-Stop Operation WITH SUCTION SHUT-OFF UNIT FOR APLICATION AGAINST NEGATIVE HEAD 25.100.181.021 ISSUE 3 5-97 IM 25.055AC UA (C/6-01)
  • Page 39 AUTOMATIC CHLORINATOR - 3000LB/24HR 2" INJECTOR - FLOW DIAGRAM Prime & Flush Operation 25.100.181.031 ISSUE 3 5-77 IM 25.055AC UA (C/6-01)
  • Page 40 AUTOMATIC CHLORINATOR - 3000LB/24HR DISENGAGE THE MOTOR BY PULLING THE KNOB OUTWARD. ADJUST THE GAS FEED RATE AS DESIRED BY ROTATING THE KNOB. C. TO RETURN TO AUTOMATIC CONTROL, PRESS THE KNOB AND ROTATE THE KNOB SLIGHTLY UNTIL GEAR TEETH ENGAGE. INSTRUCTIONS FOR MANUAL OPERATION - OPERATION Positioner 40.300.170.010...

  • Page 41: Rotameter

    AUTOMATIC CHLORINATOR - 3000LB/24HR SECTION 4 - SERVICE List Of Contents PARA./DWG. NO. General Care of Equipment........4.1 Checking for Leaks ..........4.1.1 Plastic Parts ............4.1.2 Cleaning Parts ............4.2 Inspection .............. 4.3 Tools ..............4.4 Gaskets/O-Rings ........... 4.5 Changing Gas Supply Cylinders ......

  • Page 42: Vent

    AUTOMATIC CHLORINATOR - 3000LB/24HR WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT, EXCEPT IN CASES OF LEAK DETECTION OR CALIBRATION ADJUSTMENTS, THE GAS SUPPLY MUST BE COMPLETELY SHUT OFF AT THE GAS SUPPLY CONTAINER(S), AND THE GAS IN THE SYSTEM EXHAUSTED BEFORE SERVICING THE EQUIPMENT.
  • Page 43 AUTOMATIC CHLORINATOR - 3000LB/24HR NATE IN AN AREA WHERE GAS FUMES CANNOT CAUSE INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT. DO NOT TERMINATE THE EXHAUST SYSTEM AT A LOCATION ROUTINELY USED BY PERSONNEL, SUCH AS WORK AREAS OR PATHWAYS, NOR NEAR WINDOWS OR VENTILATION SYSTEM INTAKES.
  • Page 44 AUTOMATIC CHLORINATOR - 3000LB/24HR SOLVENTS CAN PRODUCE SERIOUS PHYSIOLOGICAL EF- FECTS UNLESS USED IN STRICTEST COMPLIANCE WITH THE SOLVENT MANUFACTURER’S SAFETY RECOMMENDA- TIONS. All traces of detergent or moisture must be removed from the parts before they are returned to service. Do not use heat on plastic parts. Inspection After the disassembled parts are cleaned, and prior to reassembly, perform the following:...

  • Page 45: Installation Of Throat And Tailway

    AUTOMATIC CHLORINATOR - 3000LB/24HR Injector The injector is a highly important part of the gas feeder. Proper operation of the system depends upon good injector performance. Each gas feeder is equipped with an injector that is selected at the factory to suit the installation conditions.
  • Page 46 Pull plug straight down until the plug is free. f. Reassemble in reverse order. 4.11 Maintenance Maintenance of a Series V-2000 Gas Feeder consists of three periodically performed operations: • Periodic Performance Checks to detect the onset of any deteriorating conditions before their progress leads to serious malfunction.
  • Page 47 AUTOMATIC CHLORINATOR - 3000LB/24HR b. With the injector still operating, turn off the gas at the supply con- tainer valve. In a few moments the vacuum gauge should indicate 100 inches of water and the indicator on the front of the vacuum regulator should move to the EMPTY position.
  • Page 48 AUTOMATIC CHLORINATOR - 3000LB/24HR 4.11.2 Cleaning At intervals as tabulated below: t a l i t c r e t s t i c i t . r e & NOTE: The actual frequency of cleaning will depend on calendar time, the feed rate and amount of gas fed, the care exercised in cylin- der changing, the source of gas, and the quality of the operating water.
  • Page 49 AUTOMATIC CHLORINATOR - 3000LB/24HR hold the tube, half full with water, with palms capping the ends, and shake vigorously endwise for a few seconds. Discharge the water and repeat until clean. A common pipe cleaner may be used to scrub the interior.

  • Page 50: Injector Water Supply

    AUTOMATIC CHLORINATOR - 3000LB/24HR time, float movement in the rotameter is not proportional to V-notch plug adjustment, as shown by a sudden marked rise or drop for a small amount of plug adjustment, the V-notch plug requires cleaning. a. Turn the knob on the vacuum regulator(s) to OFF. After the supply vacuum gauge reads 100 inches of water and the rotameter float rests on the bottom stop, shut off the injector water supply.
  • Page 51 AUTOMATIC CHLORINATOR - 3000LB/24HR WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIP-MENT DAMAGE WHEN USING HYDROCHLORIC ACID, OBSERVE ALL SAFETY PRECAUTIONS RECOM- MENDED BY THE ACID MANUFACTURER/SUPPLIER. If the upstream strainer becomes corroded or perforated and passes a small pebble or other tramp material, such particles can partially plug the throat and prevent adequate flow.
  • Page 52 AUTOMATIC CHLORINATOR - 3000LB/24HR e. Unscrew valve stem (8) in the center of the top of the upper body (32). Wipe the surface of the spherical tip of valve stem with a clean cloth or paper towel to remove any loose material. Soak briefly in 10% muriatic (hydrochloric) acid if there are any depos- its that do not wipe away with plain water.
  • Page 53 AUTOMATIC CHLORINATOR - 3000LB/24HR • Cleaning Injector Unit Diaphragm Backcheck. a. Shut off injector operating water. b. Take steps to prevent water flowing back toward the injector from the point of application. c. Unscrew gas line tubing nut and remove tubing. d.
  • Page 54 AUTOMATIC CHLORINATOR - 3000LB/24HR f. Proceed to paragraph c for the anti-syphon portion of the injec- tor. • Cleaning Anti-Syphon Injector Lower Portion a. Unscrew lower union nut (10), carefully remove bottom cap, and take out diaphragm assembly. Clean off any deposits with warm (110°-125°F) water.
  • Page 55 AUTOMATIC CHLORINATOR - 3000LB/24HR ACID, OBSERVE ALL SAFETY PRECAUTIONS RECOM- MENDED BY THE ACID MANUFACTURER/SUPPLIER. f. Wipe a thin film of Halocarbon grease on the O-ring (5) before installing it on the stem. g. Look through the opening in the top of the injector with a flash- light and examine the conical hole and O-ring in diaphragm screw immediately below.
  • Page 56 AUTOMATIC CHLORINATOR - 3000LB/24HR d. Install a new O-ring on the poppet and insert the poppet into the holder. e. Assemble the holder (34) to the injector body. Do not use exces- sive force when tightening the adapter. f. Replace the union nut O-ring (16) before reconnecting the gas line.
  • Page 57 AUTOMATIC CHLORINATOR - 3000LB/24HR m. Secure the tailway with the retaining nut and connect to the operation water tubing. n. Connect the gas line. o. Check for tightness and function. 4.12 Periodic Preventive Maintenance Because of aging of elastomeric components and the desirability of check- ing internal zones for possible accumulations of deposits not seen in rou- tine maintenance, it is recommended that, at one-year intervals, each of the principal components of the system be completely disassembled.

  • Page 58: Drain

    AUTOMATIC CHLORINATOR - 3000LB/24HR 4.12.3 Replacement of Bellofram (See Dwg. 25.052.001.046) Damage to the bellofram (16) is indicated by a continuous flow of water from the injector shut-off valve drain when the valve is in the OFF position or by failure of the injector to operate when the valve is in the ON position. To replace the bellofram, proceed as follows: a.
  • Page 59 AUTOMATIC CHLORINATOR - 3000LB/24HR d. Remove diaphragm (6). Remove machine screws (4). Remove and discard gaskets (7). • Reassembly a. Refer to the cleaning procedure and clean the parts prior to reas- sembly. b. Wipe a thin film of Halocarbon grease onto all O-rings. c.
  • Page 60 Table 4.1 - Troubleshooting With a Manometer and Vacuum Gauge l u f l l u h t i . s t . t n l i a i t c s i l . e t c i f h t i i t a r e t...
  • Page 61 Table 4.1 - Troubleshooting With a Manometer and Vacuum Gauge (Cont'd) t a l s l l . r e h t i t a l r h t i l t . t i i c i y l t i l e .
  • Page 62 Table 4.1 - Troubleshooting With a Manometer and Vacuum Gauge (Cont'd) i t c t a l r t s . r e e f f l a i i l e i t a r e t i t c r e t .
  • Page 63 Table 4.1 - Troubleshooting With a Manometer and Vacuum Gauge (Cont'd) . l a r e t v i t ) . e J " " . l o r t s i l e i t a . r e t a l r e t .
  • Page 64 Table 4.1 - Troubleshooting With a Manometer and Vacuum Gauge (Cont'd) i t n . y l t f a h t i , l a h t i l i f r t s l l a , s t , h t r i f i l s...
  • Page 65 AUTOMATIC CHLORINATOR - 3000LB/24HR WARNING LABELS AND TAGS The following warning labels and tags are attached to the equipment. ------------------------------------------------------------------------------------ L2016: TO AVOID POSSIBLE SEVERE PERSONAL INJURY FROM ELECTRICAL SHOCK, TURN OFF POWER BEFORE SERVICING. ------------------------------------------------------------------------------------ L2708: CHLORINE, WHICH IS A HAZARDOUS CHEMICAL, IS PRESENT IN THIS EQUIPMENT DURING NORMAL OPERATION.
  • Page 66 AUTOMATIC CHLORINATOR - 3000LB/24HR WARNING LABELS AND TAGS (CONT'D) 8. The USF/W&T instruction book provided with this equip- ment furnishes complete and detailed instructions for its installation, operation, and maintenance and must be referred to for that detailed information. 9. The USF/W&T instruction book provided with this equip- ment also furnishes technical information on the charac- teristics, storage, and handling of chlorine, and must be referred to for that information.

  • Page 67: Im 25.055Ac Ua (C/6

    AUTOMATIC CHLORINATOR - 3000LB/24HR CAUTION LABELS AND TAGS The following caution labels and tags are attached to the equipment. ------------------------------------------------------------------------------------ L2076: DO NOT DISASSEMBLE DIAPHRAGM UNIT FROM PRESSURE SENSOR. ------------------------------------------------------------------------------------ P4373: PULL OUT STEM TO FULL LENGTH OF CHAIN BE- FORE CLOSING VALVE.

  • Page 68: Installation

    AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: FOR INSTRUCTIONS, SEE DWG. 25.055.151.010B. INSTALLATION OF ROTAMETER - SERVICE 25.055.151.010A ISSUE 0 4-92 IM 25.055AC UA (C/6-01)

  • Page 69: Operation

    AUTOMATIC CHLORINATOR - 3000LB/24HR TO INSTALL ROTAMETER a. Remove the control unit front cover by gripping ft on the sides near the bottom. Swing it out while pushing up. b. Join the stops together to form a cross and insert the stops in the outlet assembly with the circular cutouts up. c.

  • Page 70: Service

    AUTOMATIC CHLORINATOR - 3000LB/24HR THE PLUG IS AT THE ZERO POSITION WHEN THE SCRATCH LINE ON THE PLUG IS IN LINE WITH THE BOTTOM OF THE ORIFICE. THIS RESULTS WHEN THE ELECTRONIC CONTROLLER IS RECEIVING A ZERO SIGNAL. IF ADJUSTMENTS ARE NECESSARY: RETRACT RACK AND THEN LOOSEN NUT.

  • Page 71: Illustrations

    AUTOMATIC CHLORINATOR - 3000LB/24HR SECTION 5 - ILLUSTRATIONS List Of Contents DRAWING NO. Parts Basic Components ..........25.055.000.052A-D Chlorine Rotameter ..........25.056.005.010A&B V-Notch Plug Components ........ 25.056.004.010 Vacuum Differential Regulating Valve ....25.056.003.010A&B 2" Injector - With Pressure-Operated Plug Shut-Off ............25.052.001.046A&B 2"...
  • Page 72 AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWGS. 25.055.000.052C&D. SERIES V-2000 GAS FEEDER - PARTS 25.055.000.052A ISSUE 0 8-97 IM 25.055AC UA (C/6-01)
  • Page 73 AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE SERIES V-2000 GAS FEEDER - PARTS DWGS. 25.055.000.052C&D. 25.055.000.052B ISSUE 1 02-00 IM 25.055AC UA (C/6-01)
  • Page 74 AUTOMATIC CHLORINATOR - 3000LB/24HR WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. SERIES V-2000 GAS FEEDER - PARTS LIST 25.055.000.052C ISSUE 0 8-97 IM 25.055AC UA (C/6-01)
  • Page 75 AUTOMATIC CHLORINATOR - 3000LB/24HR WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. SERIES V-2000 GAS FEEDER - PARTS LIST 25.055.000.052D ISSUE 1 02-00 IM 25.055AC UA (C/6-01)
  • Page 76 AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.056.005.010B. CHLORINE ROTAMETER - PARTS 25.056.005.010A ISSUE 0 6-93 IM 25.055AC UA (C/6-01)
  • Page 77 AUTOMATIC CHLORINATOR - 3000LB/24HR WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. CHLORINE ROTAMETER - PARTS LIST 25.056.005.010B ISSUE 0 6-93 IM 25.055AC UA (C/6-01)
  • Page 78 AUTOMATIC CHLORINATOR - 3000LB/24HR V-NOTCH PLUG COMPONENTS - PARTS 25.056.004.010 ISSUE 0 6-93 IM 25.055AC UA (C/6-01)
  • Page 79 AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.056.003.010B. AAA7130 VACUUM DIFFERENTIAL REGULATING VALVE - PARTS 25.056.003.010A ISSUE 0 05-00 IM 25.055AC UA (C/6-01)
  • Page 80 AUTOMATIC CHLORINATOR - 3000LB/24HR WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. AAA7130 VACUUM DIFFERENTIAL REGULATING VALVE - PARTS LIST 25.056.003.010B ISSUE 0 05-00 IM 25.055AC UA (C/6-01)
  • Page 81 AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.052.001.046B. U25762 SMALL THROAT U25763 LARGE THROAT 2" INJECTOR - PARTS With Pressure-Operated Plug Shut-Off 25.052.001.046A ISSUE 0 10-95 IM 25.055AC UA (C/6-01)
  • Page 82 AUTOMATIC CHLORINATOR - 3000LB/24HR WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. U25762 SMALL THROAT U25763 LARGE THROAT 2" INJECTOR - PARTS LIST With Pressure-Operated Plug Shut-Off 25.052.001.046B ISSUE 0 10-95 IM 25.055AC UA (C/6-01)
  • Page 83 AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.052.001.051B. U25764 SMALL THROAT U25765 LARGE THROAT 2" INJECTOR - PARTS With Manually Operated Plug Shut-Off 25.052.001.051A ISSUE 6 05-00 IM 25.055AC UA (C/6-01)
  • Page 84 AUTOMATIC CHLORINATOR - 3000LB/24HR " 4 " 2 " 6 " 8 " 6 " 4 " 6 " 4 " 6 & " 4 " 1 " 2 " 4 " 8 WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. U25764 SMALL THROAT;...
  • Page 85 AUTOMATIC CHLORINATOR - 3000LB/24HR WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. U19315 INJECTOR SHUT-OFF UNIT - PARTS 25.100.06.111 ISSUE 6 2-93 IM 25.055AC UA (C/6-01)
  • Page 86 AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.200.002.030B. AAA4316 1” STANDARD INJECTOR - PARTS 25.200.002.030A ISSUE 0 10-95 IM 25.055AC UA (C/6-01)
  • Page 87 AUTOMATIC CHLORINATOR - 3000LB/24HR WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. AAA4316 1” STANDARD INJECTOR - PARTS LIST 25.200.002.030B ISSUE 0 10-95 IM 25.055AC UA (C/6-01)
  • Page 88 AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.055.000.017B. JUNCTION BOX - PARTS 25.055.000.017A ISSUE 0 6-97 IM 25.055AC UA (C/6-01)
  • Page 89 AUTOMATIC CHLORINATOR - 3000LB/24HR " 8 " 4 " 2 WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. JUNCTION BOX - PARTS LIST 25.055.000.017B ISSUE 0 6-97 IM 25.055AC UA (C/6-01)
  • Page 90 AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.200.002.040B. AAA4313 1” ANTI-SYPHON INJECTOR - PARTS 25.200.002.040A ISSUE 0 10-95 IM 25.055AC UA (C/6-01)
  • Page 91 AUTOMATIC CHLORINATOR - 3000LB/24HR WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. AAA4313 1” ANTI-SYPHON INJECTOR - PARTS LIST 25.200.002.040B ISSUE 0 10-95 IM 25.055AC UA (C/6-01)
  • Page 92 AUTOMATIC CHLORINATOR - 3000LB/24HR SOLUTION HOSE MAY BE CONNECTED DIRECTLY TO THE INJECTOR TAILWAY. IF RIGID PVC PIPE IS USED, A PIECE OF STRAIGHT PIPE AT LEAST EIGHT INCHES LONG SHOULD BE COUPLED TO THE END OF THE INJECTOR TAILWAY BEFORE ANY ELBOWS, TEES, OR SIMILAR FLOW RESTRICTIONS ARE USED.
  • Page 93 AUTOMATIC CHLORINATOR - 3000LB/24HR ASSEMBLY NOTES: ASSEMBLE THROAT, TWO O-RINGS, AND TAILPIECE AS SHOWN, BEFORE INSERTING IN INJECTOR BODY. ORDERING INFORMATION: STANDARD COMBINATION WHEN HYDRAULIC CONDITIONS PERMIT. NON-STANDARD COMBINATION, MAY BE USED IF REQUIRED. IF NO SYMBOL IS INDICATED, COMBINATION CANNOT BE USED. WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS.
  • Page 94 AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.200.002.010B. AAA4310 3/4” STANDARD INJECTOR - PARTS 25.200.002.010A ISSUE 0 10-95 IM 25.055AC UA (C/6-01)
  • Page 95 AUTOMATIC CHLORINATOR - 3000LB/24HR " 4 " 1 " 6 " 6 " 4 WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. AAA4310 3/4” STANDARD INJECTOR - PARTS LIST 25.200.002.010B ISSUE 2 7-99 IM 25.055AC UA (C/6-01)
  • Page 96 AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.200.002.020B. AAA4307 3/4” ANTI-SYPHON INJECTOR - PARTS 25.200.002.020A ISSUE 2 6-01 IM 25.055AC UA (C/6-01)
  • Page 97 AUTOMATIC CHLORINATOR - 3000LB/24HR " 4 " 1 " 6 " 4 " 4 " 8 " 2 " 6 " 4 " 2 " 6 " 8 " 6 WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. AAA4307 3/4”...
  • Page 98 AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: DOES NOT INCLUDE CORPORATION COCK. ORDER SEPARATELY, SPECIFYING PIPE THREAD. WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. MAIN CONNECTION - PARTS For Hose 50.845.02.011 ISSUE 6 2-82 IM 25.055AC UA (C/6-01)
  • Page 99 AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: PART OF SOLUTION TUBE U26131. PART OF CORPORATION COCK U617 OR U638. WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR DAMAGE TO EQUIPMENT, DO NOT EXCEED WORKING PRESSURE OF HOSE OR FLEXIBLE PLASTIC PIPE. NEVER EXCEED 125 PSI AT 70° F. USE RIGID PIPE BETWEEN DISCHARGE AND MAIN CONNECTIONS WHEN PUMPING HAZARDOUS CHEMICALS.
  • Page 100 AUTOMATIC CHLORINATOR - 3000LB/24HR WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR DAMAGE TO EQUIPMENT, DO NOT EXCEED WORKING PRESSURE OF HOSE OR FLEXIBLE PLASTIC PIPE. NEVER EXCEED 100 PSI AT 70° F. USE RIGID PIPE BETWEEN DISCHARGE AND MAIN CONNECTIONS WHEN PUMPING HAZARDOUS CHEMICALS.
  • Page 101 AUTOMATIC CHLORINATOR - 3000LB/24HR WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR DAMAGE TO EQUIPMENT, DO NOT EXCEED WORKING PRESSURE OF HOSE OR FLEXIBLE PLASTIC PIPE. NEVER EXCEED 125 PSI AT 70° F. USE RIGID PIPE BETWEEN DISCHARGE AND MAIN CONNECTIONS WHEN PUMPING HAZARDOUS CHEMICALS.
  • Page 102 AUTOMATIC CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.055.004.010B. MODULE ENCLOSURE - PARTS 25.055.004.010A ISSUE 3 6-97 IM 25.055AC UA (C/6-01)
  • Page 103 AUTOMATIC CHLORINATOR - 3000LB/24HR WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. MODULE ENCLOSURE - PARTS LIST 25.055.004.010B ISSUE 4 6-97 IM 25.055AC UA (C/6-01)
  • Page 104 FOR PARTS LIST, SEE DWG. 55.116.020.015B. LOW VACUUM SWITCH - AAA7808 HIGH VACUUM SWITCH - AAA9911 GAA1046 DUAL OR HIGH AND LOW VACUUM SWITCH CONNECTIONS - PARTS 3000 Lb. Series V-2000 Gas Feeder 55.116.020.015A ISSUE 0 10-99 IM 25.055AC UA (C/6-01)

  • Page 105: Parts List

    " ½ " WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. GAA1046 DUAL OR HIGH AND LOW VACUUM SWITCH CONNECTIONS - PARTS LIST 3000 Lb. Series V-2000 Gas Feeder 55.116.020.015B ISSUE 0 10-99 IM 25.055AC UA (C/6-01)
  • Page 106 AUTOMATIC CHLORINATOR - 3000LB/24HR CONNECTIONS FOR GAS FLOW TRANSMITTER AAA7427 3000LB SERIES V2000 GAS FEEDER - PARTS 55.114.010.020A ISSUE 1 02-00 IM 25.055AC UA (C/6-01)
  • Page 107 AUTOMATIC CHLORINATOR - 3000LB/24HR CONNECTIONS FOR GAS FLOW TRANSMITTER AAA7427 3000LB SERIES V2000 GAS FEEDER - PARTS 55.114.010.020B ISSUE 1 02-00 IM 25.055AC UA (C/6-01)
  • Page 108 AUTOMATIC CHLORINATOR - 3000LB/24HR ¾ " ¾ " ½ " ¼ ½ " ¼ " " 1 " 6 ½ " " 7 " 1 ½ " , " ¼ , " ¼ ¼ , " WHEN ORDERING MATERIAL ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. CONNECTIONS FOR GAS FLOW TRANSMITTER AAA7427 3000LB SERIES V2000 GAS FEEDER - PARTS LIST...

  • Page 109: Preventive Maintenance Kits And Spare Parts List

    AUTOMATIC CHLORINATOR - 3000LB/24HR SECTION 6 - PREVENTIVE MAINTENANCE KITS AND SPARE PARTS LIST SERIES V-2000 CHLORINATOR 3000 LB CAPACITY DESCRIPTION PART NO. Preventive Maintenance Kit U29216 ADDITIONAL SPARE PARTS DESCRIPTION PART NO. Diaphragm (Vacuum Differential Regulating Valve) P60105 O-ring (Vacuum Differential Regulating Valve)
  • Page 110 AUTOMATIC CHLORINATOR - 3000LB/24HR IM 25.055AC UA (C/6-01)
  • Page 111 Taking care of the world’s water. Wallace & Tiernan Products 1901 West Garden Road Vineland, NJ 08360 856.507.9000 tel. 856.507.4125 fax http://www.wallaceandtiernan.usfilter.com IM 25.000AA UA ISSUE B...

  • Page 112: Technical Data

    CHLORINE HANDLING MANUAL CHLORINE HANDLING MANUAL WARNING: CHLORINE IS A HAZARDOUS CHEMICAL THAT CAN CAUSE INJURY AND DEATH IF NOT HANDLED PROPERLY. THIS MANUAL CONTAINS ONLY GENERAL INFORMATION ON THE PHYSICAL PROPERTIES, STOR- AGE, AND HANDLING OF CHLORINE. IT IS NOT INTENDED TO REPLACE OR LIMIT SAFETY PROCEDURES IN YOUR FACILITY.
  • Page 113 CHLORINE HANDLING MANUAL Table Of Contents (Cont’d) Handling Containers ............... 3.6 Using Containers ..............3.7 Piping ..................4 Piping Materials and Joints .............4.1 Gas Piping Installation Requirements ........4.2 Liquid Piping Installation Requirements ........4.3 Pressure Relief and Vent Piping Requirements ...... 4.4 Valves ..................4.5 Pressure Gauges and Switches ..........4.6 Pressure Relief Devices ............4.7...
  • Page 114 CHLORINE HANDLING MANUAL TECHNICAL DATA AND CHARACTERISTICS OF Specific Gravity, Dry Gas CHLORINE 2.48 at 32° F and 1 atm referred to air. The following general information on chlorine may be useful Specific Gravity, Liquid in planning a chlorinator installation; however, a specific 1.47 at 32°...
  • Page 115 CHLORINE HANDLING MANUAL Weight, Liquid 3.1 RATES 1 cf = 91.56 lb at 32° F. In general, using a remote vacuum type chlorinator, the maxi- Solubility in Water* mum sustained gas withdrawal rate at which chlorine may be 6.93 lbs./100 gals at 60° F and 1 atm. taken from a 100 or 150 pound cylinder is one pound per day per degree Fahrenheit (1.0 lb/24 hrs/°F).
  • Page 116 CHLORINE HANDLING MANUAL Figure 3 – Standard Cylinder Valve Figure 2 – Manifolding Cylinders 3.2 MAXIMUM LIQUID WITHDRAWAL RATE The generally accepted alternate to manifolding ton contain- ers is to withdraw liquid chlorine from the lower valve and use an evaporator. By this means, a ton container can be emptied in approximately five hours, which is equivalent to 9600 lbs/24 hrs.
  • Page 117 CHLORINE HANDLING MANUAL Cylinders are equipped with one valve that is normally used creases to 158-165° F to relieve pressure and prevent rupture for gas withdrawal. Ton containers are equipped with two of the cylinder. valves, as shown in Figure 6. Ton containers are equipped with six fusible metal plugs (see Figure 8), three of which are in each end, spaced 120 degrees apart.

  • Page 118: Handling Containers

    CHLORINE HANDLING MANUAL The chlorine inventory depends to a large extent on local availability. Consult with chlorine suppliers in the area; review appropriate fire code requirements concerning storage of oxidizing materials and other applicable laws and regula- tions. When planning space for stored containers, sufficient space must be allowed for empty containers.

  • Page 119: Using Containers

    CHLORINE HANDLING MANUAL WARNING: NEVER LIFT CYLINDERS BY THE POSITION WITH THE TWO VALVES IN A VERTI- VALVE PROTECTING HOOD. THE HOOD MAY CAL LINE. TON CONTAINERS MUST BE SECURED SEPARATE FROM THE CYLINDER, CAUSING THE IN SUCH A MANNER (E.G., CHOCKS) TO PREVENT CYLINDER TO FALL.

  • Page 120: Piping

    CHLORINE HANDLING MANUAL Tank cars are unloaded by means of one of the liquid valves. To facilitate maintenance, the number of line valves should One of the gas valves can be connected to the system to be kept to a minimum. Insulation is required only in those permit pressure testing with gaseous chlorine rather than cases where it is necessary to prevent chlorine gas lines from liquid.

  • Page 121: Liquid Piping Installation Requirements

    CHLORINE HANDLING MANUAL encountered. Do not run these gas lines along exterior walls A liquid line pressure relief system (which includes a rupture that may be cold in winter months. Do not run pressure gas disc and an expansion chamber) is required where liquid lines under windows from which cold air descends in winter may be trapped in the line or where it is necessary to run lines months.

  • Page 122: Valves

    CHLORINE HANDLING MANUAL vents must be separate from gas pressure reducing valve STEM NUT HANDLE pressure vents, etc.). The interior cross sectioned area of a BONNET PLATE common vent or pressure relief line should be approximately RETAINING RING STEM BEARING equal to the sum of the cross sectional areas of the individual INDICATOR STOP STEM SEAL...

  • Page 123: Pressure Relief Devices

    CHLORINE HANDLING MANUAL 4.7 PRESSURE RELIEF DEVICES fore essential that all piping be thoroughly cleaned and dried prior to exposure to chlorine. There are two types of pressure relief devices in use in chlo- rine piping systems. The first, as shown in Figure 13, is WARNING: INCOMPLETE CLEANING CAN RE- usually employed in liquid chlorine piping to protect the SULT IN VIOLENT REACTIONS BETWEEN CHLO-...

  • Page 124: Personnel Safety

    CHLORINE HANDLING MANUAL The chlorine container valve should be opened only slightly can provide cross circulation; however, ventilation by means during this phase of testing or preferably closed again after of a proper type electric fan is always recommended. pressurizing the system. The piping should be tested in the smallest sections permitted by the existing valves to mini- In all cases, installations must comply with appropriate regu- mize the discharge of chlorine through any leaks.

  • Page 125: Safety Precautions

    CHLORINE HANDLING MANUAL The attending physician may wish to refer to a Material WARNING: REPLACE FLEXIBLE CONNECTIONS Safety Data Sheet on chlorine as well as to the Chlorine ANNUALLY, OR SOONER IF THERE IS EVIDENCE Institute’s Chlorine Manual and/or Pamphlet 63, First Aid OF DETERIORATION.

  • Page 126: Chemical Disposal Facilities

    CHLORINE HANDLING MANUAL sistance. In the United States this plan is activated through At some large installations, scrubbers have been installed so CHEMTREC (toll free 800-4249300). In Canada, contact that areas containing chlorine or chlorine equipment can be CANUTEC (call collect 613-996-6666). These names and sealed off and the air removed to a process that will absorb numbers must also be posted prominently.

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