Page 1 SERIES V-2000 CHLORINATOR 3000 Lb/24 Hr Manual Control BOOK NO. WT.025.055.004.UA.IM.0814 W3T109620...
Page 2 SERIES V-2000 CHLORINATOR 3000 LB/24 HR MANUAL CONTROL BOOK NO. WT.025.055.004.UA.IM.1009 W3T109620...
Page 3: Ordering Information
MANUAL 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 4 INTRODUCTION This instruction book provides installation, operation, and maintenance instruc- tions for the Evoqua Water Technologies Series V-2000 (Chlorine) Gas Feeder (control module and injector). Of necessity, more information is provided than applies to each specific installation; disregard those details that do not apply to your installation.
Page 5: Table Of Contents
MANUAL CHLORINATOR - 3000LB/24HR 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 .............Section 1 Installation ..............Section 2 Operation ..............Section 3 Service ................Section 4 Illustrations ..............Section 5 Preventive Maintenance Kits and Spare Parts List ............Section 6 Literature/Manuals .............Section 7...
Page 6 MANUAL 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, QUALIFIED PERSON- NEL WHO ARE THOROUGHLY FAMILIAR WITH THE ENTIRE CONTENTS OF THIS INSTRUCTION BOOK AND THE...
Page 7 MANUAL CHLORINATOR - 3000LB/24HR VERY IMPORTANT SAFETY PRECAUTIONS - CHLORINE (CONT’D) THE TWO MOST COMMON CAUSES OF CHLORINE PIPING LEAKS ARE: 1. RE-USE OF GASKETS. THIS SHOULD NEVER BE DONE. ALWAYS HAVE AN ADEQUATE SUPPLY ON HAND AND ALWAYS USE NEW GASKETS OF THE CORRECT MATERIAL AND SIZE AS IDENTIFIED ON THE EQUIPMENT PARTS DRAWING.
Page 8 MANUAL CHLORINATOR - 3000LB/24HR PROTECT YOUR EQUIPMENT INVESTMENT MINIMIZE DOWNTIME ORDER A PREVENTIVE MAINTENANCE KIT NOW ... KEEP ONE ON HAND Quality Preventive Dependable Operation Equipment Maintenance Minimum Downtime There’s no question about it. Equipment that is properly maintained is dependable equipment. It will give optimum performance with minimum unscheduled downtime.
Page 9 MANUAL 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. Date of Installation Preventive Maintenance Log Schedule Date...
Page 10 MANUAL CHLORINATOR - 3000LB/24HR REGIONAL OFFICES INSTALLATION, OPERATION, MAINTENANCE, AND SERVICE INFORMATION 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 Evoqua Water Tech- nologies, Colorado Springs, CO contact the office indicated below.
Page 11 MANUAL CHLORINATOR - 3000LB/24HR WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 13 MANUAL 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 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 14: Technical Data
MANUAL CHLORINATOR - 3000LB/24HR Technical Data Accuracy 4% of indicated flow Capacity 50 to 3000 lb/24 hr chlorine Feed Range 20 to 1 for any one rotameter Pressure at Point of 75 psi max. with flexible polyethylene for Application the solution line. 160 psi max.
Page 15 MANUAL CHLORINATOR - 3000LB/24HR V-2000 INJECTOR INLET PRESSURE LIMITS - PERFORMANCE 25.055.190.010 ISSUE 2 7-05 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 16 MANUAL CHLORINATOR - 3000LB/24HR VACUUM LINE LENGTH LIMITS - PERFORMANCE Used In Remote Vacuum Gas Feeders 25.052.190.030 ISSUE 3 5-97 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 18: Table Of Contents
Injector Arrangements for Intermittent Start-Stop Operation ..............2.16 Illustrations Typical Installation Series V-2000 Gas Feeder........... 25.055.110.035 3000lb Series V-2000 Gas Feeder ....... 25.055.110.080 2" Injector With 3/4" Ball Valve ......... 25.055.110.075 Installation Piping 2" Injector - Connections for Prime and Flush Operations .............. 25.100.006.122 2"...
Page 19: Installation
MANUAL CHLORINATOR - 3000LB/24HR WARNING: THIS CONTROL MODULE IS DESIGNED TO OPERATE UNDER VACUUM ONLY. TO AVOID POSSIBLE SEVERE 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 20 MANUAL CHLORINATOR - 3000LB/24HR 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. The proper installation of this line is important.
Page 21: Operation
MANUAL CHLORINATOR - 3000LB/24HR 2.10 Injector Water Supply The injector requires a supply of reasonably clean water. Equip the water supply up to and including two-inch sizes with a strainer, as indicated in the Typical Installation drawing in this section. The pressure and quantity of water required varies from one installation to another.
Page 22 MANUAL CHLORINATOR - 3000LB/24HR 2.13 Point of Application 2.13.1 Main Connection If the solution is to be applied in a main, a suitable pipe tap is required in the main to accommodate the solution tube or diffuser. 2.13.2 Open Well If the solution is to be applied in a basin, flume, channel, etc., where there is no pressure, the line from the injector must be supported so that the open end is submerged to the bottom of the chamber, or a minimum of six feet, if...
Page 23 MANUAL CHLORINATOR - 3000LB/24HR 2.16 Injector Arrangements For Intermittent Start-Stop Operation If the gas feeder is to be operated intermittently in conjunction with a pump or other equipment, this is usually accomplished by one of the following: • Two-inch injectors with three-way shut-off valves may be fitted with so- lenoid valves as shown in Dwgs.
Page 24 I N Q U O T A T I O N A N D A S C H E C K E D O N T H I S D R A W I N G . SERIES V-2000 GAS FEEDER - TYPICAL INSTALLATION 25.055.110.035...
Page 25 MANUAL CHLORINATOR - 3000LB/24HR NOTES: ACCESSORY ITEM FURNISHED ONLY IF SPECIFICALLY LISTED IN QUOTATION. NOT FURNISHED BY EVOQUA WATER TECHNOLOGIES. SERIES V-2000 GAS FEEDER - TYPICAL INSTALLATION Manual Control 25.055.110.080 ISSUE 1 8-14 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 26 MANUAL CHLORINATOR - 3000LB/24HR 2" INJECTOR WITH 3/4" BALL VALVE - TYPICAL INSTALLATION 25.055.110.075 ISSUE 1 4-05 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 27 MANUAL CHLORINATOR - 3000LB/24HR 2" INJECTOR - INSTALLATION PIPING Connections for Prime and Flush Operation 25.100.006.122 ISSUE 4 8-93 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 28 MANUAL CHLORINATOR - 3000LB/24HR 2" INJECTOR - INSTALLATION PIPING Connections for Manual Suction Shut-Off Unit 25.100.06.131 ISSUE 3 1-90 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 29 MANUAL CHLORINATOR - 3000LB/24HR 2" INJECTOR - INSTALLATION PIPING Connections for Intermittent Start-Stop Operation 25.100.006.142 ISSUE 2 4-93 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 30 MANUAL 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 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 31 MANUAL 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 RECOMMENDATIONS). ONE HUNDRED FEET OF PIPE WILL EXPAND OR CONTRACT AP- PROXIMATELY 0.7 INCHES FOR EVERY 10°F TEMPERATURE CHANGE.
Page 33 2" Injector Prime and Flush Operation ......3.3.3 Illustrations 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 WT.025.055.004.UA.IM.0814...
Page 34: Gas Supply
MANUAL CHLORINATOR - 3000LB/24HR Preparation For Operation WARNING: HAZARDOUS GAS IS PRESENT IN THIS EQUIPMENT DURING NORMAL OPERATION. TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT, READ THIS INSTRUCTION BOOK AND THE APPROPRIATE GAS MANUAL BEFORE CONNECTING THIS EQUIPMENT TO A SUPPLY OF GAS.
Page 35: Rotameter
MANUAL CHLORINATOR - 3000LB/24HR (3) The connection of both ends of the plastic tubing on the gas discharge line to the injector. NOTE: Vacuum leaks ahead of the rotameter, as listed in preceding step e, will result in errors in gas feed. Vacuum leaks after the rotameter, as listed in step f, may impair the performance of the injector.
Page 36: Service
MANUAL CHLORINATOR - 3000LB/24HR 3.2.4 Adjustment of Injector Fixed throat injectors are not adjustable. Other injectors may be adjusted by means of an adjusting screw or knob at the bottom of the injector. A vacuum of at least six inches of mercury is required to obtain maximum feed. If the minimum vacuum cannot be obtained, check the actual hydraulic conditions against those specified on the order before attempting any service.
Page 37 MANUAL CHLORINATOR - 3000LB/24HR Theory of Operation Evoqua Water Technologies Gas Feeders and accessories are designed to control and indicate the rate of flow of chlorine, to provide a simple means of manually setting the feed rate at any value within the range of the machine, to mix the gas with water, and to deliver the resultant solution to the point of application.
Page 38 MANUAL CHLORINATOR - 3000LB/24HR • Application Against Negative Head If the injector described above was used where a negative head existed at the injector discharge, when the injector was shut down, this suction might act on the diaphragm (G) with sufficient force that the spring (J) could not close the seat (H), with the result that gas would be drawn from the gas feeder.
Page 39 MANUAL CHLORINATOR - 3000LB/24HR V - N O T C H V A R I A B L E O R I F I C E V A C U U M D I F F E R E N T I A L R E G U L A T I N G V A L V E 2 6 "...
Page 40 MANUAL CHLORINATOR - 3000LB/24HR 2" INJECTOR - FLOW DIAGRAM Manually Operated 25.100.181.011 ISSUE 4 5-97 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 41 MANUAL CHLORINATOR - 3000LB/24HR 2" INJECTOR - FLOW DIAGRAM Intermittent Start-Stop Operation 25.100.181.021 ISSUE 3 5-97 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 42 MANUAL CHLORINATOR - 3000LB/24HR 2" INJECTOR - FLOW DIAGRAM Prime & Flush Operation 25.100.181.031 ISSUE 4 5-97 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 44: Illustrations
MANUAL 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 45 MANUAL CHLORINATOR - 3000LB/24HR WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT, EXCEPT IN CASES OF LEAK DETECTION OR CALIBRA- TION ADJUSTMENTS, THE GAS SUPPLY MUST BE COMPLETELY SHUT OFF AT THE GAS SUPPLY CONTAINER(S), AND THE GAS IN THE SYSTEM EX- HAUSTED BEFORE SERVICING THE EQUIPMENT.
Page 46 MANUAL CHLORINATOR - 3000LB/24HR As a routine practice, check gas connections for leaks once a day. Green or reddish deposits on metal parts indicate possible leaks. No gas odor should be in evidence around equipment, except when a joint is temporarily opened. CAUTION: When any connection is broken even for a short time, immediately plug the resultant openings with a rubber stopper or equivalent to prevent the entrance of moisture.
Page 47 MANUAL CHLORINATOR - 3000LB/24HR b. Discard and replace all removed O-rings, seals, and gaskets. c. Check diaphragms for chafing or cracking. Replace damaged diaphragms. Tools When working with screws, bolts, nuts, and other hardware, use the proper size tools to avoid damage to screw heads, nuts, etc. This precaution will make it easier to remove these parts when necessary.
Page 48: Preventive Maintenance Kits And Spare Parts List
Pull plug straight down until the plug is free. 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 49 MANUAL CHLORINATOR - 3000LB/24HR PROTECT YOUR EQUIPMENT INVESTMENT MINIMIZE DOWNTIME REORDER A PREVENTIVE MAINTENANCE KIT NOW KEEP ONE ON HAND NOTE: If the gas feeder is used seasonally or with a long-term shutdown, the preventive maintenance should be performed prior to startup. 4.11.1 Performance Check To assure that all elements of your system are functioning in a normal man-...
Page 50 MANUAL CHLORINATOR - 3000LB/24HR e. Close the supply container valve(s). Shut off the injector and let normal backpressure remain. Remove the tubing from the gas inlet connection at the injector. Note if any water drips from the end of the disconnected tubing (there should be none) and leave the tubing disconnected for ap- proximately 10 minutes.
Page 51 MANUAL CHLORINATOR - 3000LB/24HR 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 bot- tom stop, turn off the injector operating water. b.
Page 52: Injector Water Supply
MANUAL CHLORINATOR - 3000LB/24HR 4.11.4 Cleaning V-Notch Plug (See Dwg. 25.055.000.052) The same contaminants seen in the rotameter are in the gas stream flowing through the V-notch orifice and may also deposit at this point. When the rota- meter is cleaned, clean the V-notch plug at the same time. If, at any 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.
Page 53 MANUAL CHLORINATOR - 3000LB/24HR WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIP- MENT DAMAGE WHEN USING HYDROCHLORIC ACID, OBSERVE ALL SAFETY PRECAUTIONS RECOMMENDED 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 54 MANUAL CHLORINATOR - 3000LB/24HR WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIP- MENT DAMAGE WHEN USING HYDROCHLORIC ACID, OBSERVE ALL SAFETY PRECAUTIONS RECOMMENDED BY THE ACID MANUFACTURER/SUPPLIER. Using a blunt tool, remove the O-ring (31) from the valve seat (9) (diaphragm clamping screw).
Page 55 MANUAL 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 deposits that do not wipe away with plain water.
Page 56 MANUAL CHLORINATOR - 3000LB/24HR c. Remove spring (22) and wipe off any deposits found. d. Reinstall spring and diaphragm assembly into bottom cap. Reassemble bottom cap to body with union nut. 4.11.8 Cleaning 1" Fixed Throat Injector (Standard) (See Dwg. 25.200.002.030) •...
Page 57 MANUAL CHLORINATOR - 3000LB/24HR WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIP- MENT DAMAGE WHEN USING HYDROCHLORIC ACID, OBSERVE ALL SAFETY PRECAUTIONS RECOMMENDED BY THE ACID MANUFACTURER/SUPPLIER. Reassemble the valve stem (11) to the upper body (13) and replace the valve seat O-ring (8) and diaphragm clamping O-ring (outer).
Page 58 MANUAL CHLORINATOR - 3000LB/24HR Press out the poppet seat (18). Replace the poppet seat along with the O- ring (20). Press in the new seat using a round rod or plastic tube (16 mm) with a flat front. Place the poppet into the guide (25) and screw in the clamping nut (33) with the assembled parts.
Page 59: Drain
MANUAL CHLORINATOR - 3000LB/24HR 4.12.2 Removal of Injector Plug (2" Bellofram Type Injector, Dwg. 25.052.001.046) CAUTION: If the injector plug is to be removed for cleaning or replacement, it is essential that the plug rod (6) be held with a wrench so it cannot rotate when the plug is unscrewed.
Page 60 MANUAL 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 reassembly. b. Wipe a thin film of halocarbon grease onto all o-rings. c.
Page 61 MANUAL CHLORINATOR - 3000LB/24HR WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 62 MANUAL CHLORINATOR - 3000LB/24HR WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 63 MANUAL CHLORINATOR - 3000LB/24HR WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 64 MANUAL CHLORINATOR - 3000LB/24HR WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 65 MANUAL CHLORINATOR - 3000LB/24HR WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 66 MANUAL 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 ELECTRI- CAL SHOCK, TURN OFF POWER BEFORE SERVICING. ---------------------------------------------------------------------------------------------------- L2708: CHLORINE, WHICH IS A HAZARDOUS CHEMICAL, IS PRESENT IN THIS EQUIPMENT DURING NORMAL OPERATION.
Page 67 MANUAL CHLORINATOR - 3000LB/24HR WARNING LABELS AND TAGS (CONT'D) 8. The Evoqua Water Technologies instruction book provided with this equipment furnishes complete and detailed instruc- tions for its installation, operation, and maintenance and must be referred to for that detailed information. 9.
Page 68 MANUAL 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 SEN- SOR. ---------------------------------------------------------------------------------------------------- P4373: PULL OUT STEM TO FULL LENGTH OF CHAIN BEFORE CLOSING VALVE.
Page 69 MANUAL CHLORINATOR - 3000LB/24HR NOTE: FOR INSTRUCTIONS, SEE DWG. 25.055.151.010B. INSTALLATION OF ROTAMETER - SERVICE 25.055.151.010A ISSUE 0 4-92 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 70 MANUAL 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 71 MANUAL CHLORINATOR - 3000LB/24HR WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 73 MANUAL CHLORINATOR - 3000LB/24HR SECTION 5 - ILLUSTRATIONS List Of Contents DRAWING NO. Parts Basic Components ............ 25.055.000.052A-D Chlorine Rotameter Components......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 ..............
Page 74 MANUAL 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 1 9-08 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 75 MANUAL 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 2 9-08 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 76 MANUAL 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 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 77 MANUAL 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 2 9-08 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 78 MANUAL CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.056.005.010B. CHLORINE ROTAMETER - PARTS 25.056.005.010A ISSUE 1 4-05 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 79 MANUAL CHLORINATOR - 3000LB/24HR KEY NO. PART NO. QTY. DESCRIPTION  P44091 aDaPTER OR P60139 aDaPTER   P44121 O-RING, HYPaLON 21/32" ID x 1-1/16" OD OR P37541 GaSKET  ---- STOP, BOTTOM (SEE TaBLE) ---- TUBE (SEE TaBLE) ---- FLOaT (SEE TaBLE) ---- STOP, TOP (SEE TaBLE) P35288 STOP  P35289 STOP  P34597 SEaL RING  50-150 LB/24 HR  250-2000 LB/24 HR  3000 LB/24 HR...
Page 80 MANUAL CHLORINATOR - 3000LB/24HR ROTAMETER MAX. CAPACITY FLOAT STOPS COMPLETE LBS. PER TUBE PART UNIT DESCRIPTION BOTTOM 24 HRS. NUMBER UXA20945 PXA44062 P37705 1/4" DIA. RED BALL P41212 P38131 UXB20945 PXA44063 P37706 5/16" DIA. RED BALL P41212 P38131 UXC20945 PXA44064 P37706 5/16"...
Page 81 MANUAL CHLORINATOR - 3000LB/24HR DIFFERENTIAL SEAT CAPACITY - LB/24 HR SEAT SULFUR CARBON CHLORINE AMMONIA MANUAL ELECTRIC DIOXIDE DIOXIDE PXA39592 PXA39592 PXE39592 PXB39592 PXE39592 PXB39592 1000 PXE39592 PXC39592 1500 1425 1150 PXE39592 PXD39592 2000 1900 1500 PXE39592 PXE39592 3000 1450 2800 2250 PXG39592...
Page 82 MANUAL 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 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 83 MANUAL 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 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 84 MANUAL 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 5 4-05 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 85 MANUAL CHLORINATOR - 3000LB/24HR KEY NO. PART NO. QTY. DESCRIPTION PXA40550 TAILWAY - LARGE THROAT (USED IN U25763) PXA40549 TAILWAY - SMALL THROAT (USED IN U25762) P34569 FLANGE PXA40554 THROAT - LARGE (USED IN U25763) PXA40553 THROAT - SMALL (USED IN U25762) AAC5921 PLUG - LARGE (USED IN U25763) AAC5918...
Page 86 MANUAL CHLORINATOR - 3000LB/24HR 21 22 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 9 7-05 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 87 MANUAL CHLORINATOR - 3000LB/24HR KEY NO. PART NO. QTY. DESCRIPTION PXA40549 TAILWAY - SMALL THROAT - USED IN U25764 PXA40550 TAILWAY - LARGE THROAT - USED IN U25765 P34569 FLANGE P41329 O-RING (228), BUNA-N, 2-1/4"ID x 2-1/2"OD PXA40553 SMALL THROAT - USED IN U25764 PXA40554 LARGE THROAT - USED IN U25765 AAC5921...
Page 88 MANUAL 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 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 89 MANUAL CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.200.002.030B. AAA4316 1" STANDARD INJECTOR - PARTS 25.200.002.030A ISSUE 1 2-09 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 90 MANUAL CHLORINATOR - 3000LB/24HR KEY NO. PART NO. QTY. DESCRIPTION P97062 DIAPHRAGM P97045 ANM4147 SPRING P97042 LOWER BODY PXA26784 O-RING (114) VITON, 5/8" ID x 13/16" OD ADH4733 CAUTION LABEL AAD2584 SEAT P97342 O-RING (VITON) 11 MM AAA1905 SCREW, MONEL P97046 WASHER P97048...
Page 91 MANUAL CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.055.000.017B. JUNCTION BOX - PARTS 25.055.000.017A ISSUE 0 6-97 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 92 MANUAL CHLORINATOR - 3000LB/24HR KEY NO. PART NO. QTY. DESCRIPTION W2T10378 ENCLOSURE AND PANEL DETAIL W2T14503 TERMINAL BLOCK W2T10235 MARKER STRIP W2T12151 MARKER STRIP W2T18718 6-32 x 5/8" LG. SCREW W2T15609 GROUND CONNECTION W2T12070 1/4" MONEL WASHER, LK W2T19386 SCREW, MACH., RD., HD. SLOT, 1/4-20 x 1/2" LG W2T417965 SS JAM HEX NUT 1/4-20 W2T15974...
Page 93 MANUAL CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.200.002.040B. AAA4313 1" ANTI-SYPHON INJECTOR - PARTS 25.200.002.040A ISSUE 1 3-09 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 94 MANUAL CHLORINATOR - 3000LB/24HR KEY NO. PART NO. QTY. DESCRIPTION P97062 DIAPHRAGM P97045 ANM4147 SPRING P96970 LOWER BODY PXA26784 O-RING (114) VITON, 5/8" ID x 13/16" OD ADH4733 CAUTION LABEL AAD2584 SEAT P97342 O-RING (VITON) 11 MM AAA1905 SCREW, MONEL P97046 WASHER P97048...
Page 95 MANUAL 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. THIS IS TO PREVENT ANY FLOW DISTURBANCES THAT COULD AFFECT THE HYDRAULIC PERFORMANCE OF TAILWAY CONNECTIONS.
Page 96 MANUAL CHLORINATOR - 3000LB/24HR " 4 " 1 " 4 " 1 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.
Page 97 MANUAL CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.200.002.010B. AAA4310 3/4" STANDARD INJECTOR - PARTS 25.200.002.010A ISSUE 2 5-04 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 98 MANUAL CHLORINATOR - 3000LB/24HR KEY NO. PART NO. QTY. DESCRIPTION AAA1547 INLET/POPPET SEAT 1/4" NPT PXA41332 O-RING (120) VITON, 1" ID x 1-3/16" OD ANM3591 O-RING, POPPET P97032 POPPET P48655 SPRING, POPPET CK. P31295 PLUG, 1/4 NPT ADH4733 CAUTION LABEL P97034 STEM AAB4087...
Page 99 MANUAL 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 5 1-09 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 100 MANUAL CHLORINATOR - 3000LB/24HR KEY NO. PART NO. QTY. DESCRIPTION AAA1547 INLET/POPPET SEAT 1/4" NPT PXA41332 O-RING (120) VITON, 1" ID x 1-3/16" OD ANM3591 O-RING, POPPET P97032 POPPET P48655 SPRING, CK. VALVE P31295 PLUG, PVC, 1/4" NPT ADH4733 CAUTION LABEL P97034 VALVE STEM AAB4087...
Page 101 MANUAL 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 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 102 MANUAL 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 103 MANUAL 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 104 MANUAL 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 105 MANUAL CHLORINATOR - 3000LB/24HR NOTE: FOR PARTS LIST, SEE DWG. 25.055.004.010B. MODULE ENCLOSURE - PARTS N O T E : F O R P A R T S L I S T S E E D W G . 2 5 . 0 5 5 . 0 0 4 . 0 1 0 B W H E N O R D E R I N G M A T E R I A L A L W A Y S S P E C I F Y M O D E L A N D S E R I A L N U M B E R O F A P P A R A T U S 25.055.004.010A...
Page 106 MANUAL CHLORINATOR - 3000LB/24HR WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS. MODULE ENCLOSURE - PARTS LIST 25.055.004.010B ISSUE 7 3-05 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 107 NOTES: 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 2 7-14 WT.025.055.004.UA.IM.0814 EVOQUA...
Page 108: Parts List
STRAP, CBL, OT 01.74 DIA., NY P39233 HALF UNION 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 1 9-08 WT.025.055.004.UA.IM.0814 EVOQUA...
Page 109 MANUAL CHLORINATOR - 3000LB/24HR CONNECTIONS FOR GAS FLOW TRANSMITTER - PARTS Manually Operated 3000 Lb. Series V2000 Gas Feeder 55.114.010.120A NOTE: FOR PARTS LIST, SEE DWG. 55.114.010.120C. ISSUE 0 05-00 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 110 MANUAL CHLORINATOR - 3000LB/24HR CONNECTIONS FOR GAS FLOW TRANSMITTER - PARTS Manually Operated 3000 Lb. Series V2000 Gas Feeder 55.114.010.120B NOTE: FOR PARTS LIST, SEE DWG. 55.114.010.120C. ISSUE 0 05-00 WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 111 MANUAL 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 - PARTS LIST Manually Operated 3000 Lb.
Page 112 MANUAL CHLORINATOR - 3000LB/24HR WT.025.055.004.UA.IM.0814 EVOQUA W3T109620...
Page 114 MANUAL 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 116 CHLORINE HANDLING MANUAL BOOK NO. WT.025.000.001.UA.IM.0614 W3T98244...
Page 117 CHLORINE HANDLING MANUAL REGIONAL OFFICES INSTALLATION, OPERATION, MAINTENANCE, AND SERVICE INFORMATION 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 Evoqua Water Tech- nologies, Colorado Springs, CO contact the office indicated below.
Page 118 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 INFORMA- TION ON THE PHYSICAL PROPERTIES, STORAGE, AND HANDLING OF CHLORINE. IT IS NOT INTENDED TO REPLACE OR LIMIT SAFETY PROCEDURES IN YOUR FACILITY. SAFETY PROCEDURES IN AN INDUSTRIAL SETTING MUST BE DESIGNED IN AC- CORDANCE WITH ALL GOVERNMENTAL REGULATIONS AND NATIONAL SAFETY CODES, AFTER GIVING FULL CONSIDERATION TO THE SPECIFIC NEEDS OF THE...
Page 119 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 ..................
Page 120 CHLORINE HANDLING MANUAL TECHNICAL DATA AND CHARACTERISTICS OF CHLO- Specific Gravity, Dry Gas RINE 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 ap- 1.47 at 32°...
Page 121 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 Solubility in Water* maximum sustained gas withdrawal rate at which chlorine 6.93 lbs./100 gals at 60° F and 1 atm. may be taken from a 100 or 150 pound cylinder is one pound per day per degree Fahrenheit (1.0 lb/24 hrs/°F).
Page 122 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 con- tainers 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 123 CHLORINE HANDLING MANUAL Cylinders are equipped with one valve that is normally used increases to 158-165° F to relieve pressure and prevent for gas withdrawal. Ton containers are equipped with two rupture 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 124 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 regulations. When planning space for stored containers, sufficient space must be allowed for empty containers.
Page 125 CHLORINE HANDLING MANUAL WARNING: NEVER LIFT CYLINDERS BY THE VALVE PRO- When withdrawing gas from a ton container, connection is TECTING HOOD. THE HOOD MAY SEPARATE FROM THE made to the upper valve (see Figure 6). Liquid withdrawal is CYLINDER, CAUSING THE CYLINDER TO FALL. accomplished by connecting to the lower valve.
Page 126: Vacuum Regulator
CHLORINE HANDLING MANUAL tank car pressure is the only force causing the chlorine to More complete details, along with ASTM and ANSI specifi- discharge, many cars are padded with dry air by the producer cations, can be obtained by referring to Chlorine Institute or the user.
Page 127 CHLORINE HANDLING MANUAL The expansion chamber provides an area for expansion in the If the source of gas is one or more ton containers connected event that valves at both ends of the line are closed. Relief to a manifold, install a drip leg of 1.0-inch schedule 80 seam- system placement must be based not only on length of line less steel pipe approximately 18 inches long in a tee in the but also placement of valves.
Page 128 CHLORINE HANDLING MANUAL WARNING: THE VENT LINE AND RELIEF LINE MUST TERMINATE IN AN AREA GAS FUMES CANNOT CAUSE INJURY TO PERSONNEL OR DAMAGE. DO NOT TERMI- NATE THE VENT LINE AND RELIEF LINE AT A LOCATION ROUTINELY USED BY PERSONNEL, SUCH AS WORK AREAS OR PATHWAYS NOR NEAR ANY WINDOWS OR VENTILATION SYSTEM INTAKES.
Page 129 CHLORINE HANDLING MANUAL 4.7 PRESSURE RELIEF DEVICES WARNING: INCOMPLETE CLEANING CAN RESULT IN VIOLENT REACTIONS BETWEEN CHLORINE AND THESE There are two types of pressure relief devices in use in chlorine MATERIALS. piping systems. The first, as shown in Figure 13, is usually employed in liquid chlorine piping to protect the piping from Steam cleaning is an acceptable method for removal of the rupture due to high pressure from thermal expansion of the...
Page 130 CHLORINE HANDLING MANUAL the discharge of chlorine through any leaks. 5.2 HEALTH HAZARDS WARNING: IT IS ESSENTIAL THAT PROPER BREATH- Exposure to a sufficiently high concentration of chlorine ING APPARATUS BE AVAILABLE BEFORE CHLORINE IS can result in difficulty in breathing and, if prolonged, finally ADMITTED TO ANY PIPING SYSTEM OR EQUIPMENT.
Page 131 CHLORINE HANDLING MANUAL 5.3 SAFETY PRECAUTIONS containers (i.e., valves, fusible plugs, or container wall). If these are on hand they must be used only by personnel The first steps to be taken in providing proper safety precau- thoroughly familiar with their use. The chlorine supplier tions at any facility are the selection of safety equipment to should be contacted immediately for information, assistance, be on hand, the proper location of the equipment, and the...
Page 132 CHLORINE HANDLING MANUAL The person responsible for making any of the calls listed Absorption systems have been provided at some facilities above must be sure to give the agency contacted complete to permit a leaking container to be emptied quickly if this is details including facility name, address, telephone number, deemed essential.