Attention: Mr. Thong Nguyen, Program Manager … Government...The information on this data sheet is...

Chloropac® Operations & Maintenance Manual

Client: Military Sealift Command HQ

Field Support Division, Code N75 P.O. Box 7480

Norfolk, VA 23511-4419 Attention: Mr. Thong Nguyen, Program Manager

Project Name: T-AKE Chloropac® System Installation Location: T-AKE Class Vessels

Siemens Water Technologies 2 Milltown Court, Union, NJ 07083 Tel: 908-851-2277 I Fax: 908-851-6906

SWT Work Order# 2429590

SIEMENS Chloropac® Operations & Maintenance Manual

Chloropac® Operations & Maintenance Manual

Client: Military Sealift Command HQ

Field Support Division, Code N75 P.O. Box 7480

Norfolk, VA 23511-4419 Attention: Mr. Thong Nguyen, Program Manager

Project Name: T-AKE Chloropac® System Installation Location: T-AKE Class Vessels

Siemens Water Technologies 2 Milltown Court, Union, NJ 07083 Tel: 908-851-2277/ Fax: 908-851-6906

SWT Work Order# 2429590

SIEMENS Chloropac® Operations & Maintenance Manual

SIEMENS

2 Milltown Court, Union, NJ 07083

Chloropac® Hypochlorination System Warranty

Water Technologies

Telephone (908) 851-2277

Fax (908) 851-6906

Internet www.water.siemens.com

Siemens Water Technologies warrants that its' Chloropac® System, exclusive of the Generating Cells, shall be free of defects in workmanship and materials for a period of one year from the date of invoice and further, that each Generating Cell in the Chloropac® System shall be free of defects in workmanship and materials for a period of five years from the date of invoice, when the Chloropac® System and/or Generating Cells are operated in accordance with the Instruction Manual provided.

Siemens Water Technologies shall have no liability hereunder unless it receives written notice from the Purchaser describing such defects in workmanship and materials, as soon as such defects are discovered by Purchaser, and such notice is received by Siemens Water Technologies within the warranty period specified for the equipment as described above.

Siemens Water Technologies' liability hereunder, insofar as the Chloropac® System or any of its parts (exclusive, however, of the Generating Cells) is concerned, shall be limited, at Siemens Water Technologies' option, to the repair, adjustment or replacement of such System (exclusive of the Generating Cell) or parts thereof; provided however (1) that Siemens Water Technologies in lieu of the above option reserves the right to refund to the Purchaser the purchase price actually received by Siemens Water Technologies in connection with a defective System (including the Generating Cells) and (2) that in case of a replacement or refund of the purchase price Purchaser shall, at Siemens Water Technologies' request, return such System or parts thereof f.o.b. Siemens Water Technologies' designated plant.

Siemens Water Technologies' liability hereunder, insofar as the Generating Cell in the Chloropac® System is concerned, shall be limited to the repair, or replacement for a prorated charge based upon the then-current selling price of said Generating Cell and the expired potion of the original five-year warranty period; provided, however, that in the case of replacement Purchaser shall, at Siemens Water Technologies' request, return such Generating

Cell f.o.b. Siemens Water Technologies' designated plant. expired warranty period in months

pro rate charge = current selling price x ------------total warranty period in months

The Warranty on all ancillary components or equipment not manufactured by Siemens Water Technologies but supplied in conjunction with the basic Chloropac® System as described on the purchase order shall be as offered to Siemens Water Technologies by the Manufacturer thereof for the benefit of the Purchaser.

Siemens Water Technologies assumes no liability for damages of any other kind whatsoever and under no circumstances shall Siemens Water Technologies be liable for incidental and/or consequential damages.

The information on this data sheet is for illustrative purposes only and is not a warranty by Siemens Water Technologies regarding the merchantability, fitness for use and/or performance of any product and/or license or recommendation regarding any patented or unpatented invention.

SIEMENS

ATTENTION Chloropac® System OPERATOR!!!

Do not set the Chloropac® Systems' amperes too high. This can cause overdosing.

Overdosing prevents marine fouling but can also cause corrosion of some metals in your piping system.

Water treatment capacities are described in Section II, .

DO NOT EXCEED 0.5 PPM (mg!l) CONTINUOUS DOSING WITH-OUT CONTACTING SIEMENS WATER TECHNOLOGIES FOR CONSULTATION.

Page 2 of2

SIEMENS Water Technologies

SECTION I 1.1 1.1.2 1.1.3 1.2 1.3 1.4

SECTION II 2.1 2.2 2.3 2.4 2.5 2.6 2.7

SECTION Ill 3.1 3.2 3.3 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.5

SECTION IV 4.1 4.1.1 4.2 4.2.1 4.2.2 4.3 4.3.1 4.3.2 4.3.2.2 4.3.2.3 4.3.2.4 4.3.2.5 4.3.2.6 4.3.2.7 4.3.2.8 4.3.2.9 4.3.2.10 4.3.3 4.3.3.1

TABLE OF CONTENTS

ELECTROLYTIC SODIUM HYPOCHLORITE GENERATION DESCRIPTION System Function System Components INSTALLATION OPERATION MAINTENANCE AND SERVICE

PRINCIPLES OF ELECTROLYTIC CHLORINE GENERATION THEORY OF ELECTROLYSIS EFFECTS OF CHLORINE SYSTEM SELECTION GLOSSARY GAS ELIMINATION WATER QUALITY AND PERFORMANCE GRAPHICS I DRAWINGS

Chloropac® GENERA TOR 41bs. DESCRIPTION INSTALLATION OPERATION MAINTENANCE AND SERVICE Leaks High Voltage Excessive Pressure Drop Flow Meter Disassembly and Assembly of the Generator GENERATING CELL DRAWINGS

Chloropac® SUPPLY 41bs. DESCRIPTION Specifications INSTALLATION Location Wiring OPERATION Theory of Operation Unit Components Power Input and EMI Filter Bridge Rectifier (D3) and Power Transformer (T1) Primary Control Transformer (T3) Pulse Width Modulation (PWM) control and IGBT Drivers Manual Control Power Transformer (T1) Secondary and DC Output Main Disconnect (DS1) and Main AC Fuses (F1, F2, F3) Operators, Indicating Lights I LED's and DIP Switches Grounding Field Adjustments Field Adjustments for the CP1 (Pulse Width Modulation) Board

..

SIEMENS Water Technologies Field Adjustments for the CP 2 (Chloropac® Control) Board 4.3.3.2

4.3.4 4.3.5 4.3.6 4.3.7 4.3.8 4.4 4.4.1 4.4.2 4.4.3 4.4.3.1 4.4.3.2 4.4.3.3 4.5

SECTION V 5.1 5.2 5.2.1 5.2.1. 1 5.2.1.2 5.2.1.3 5.2.1.4 5.2.1.4.1 5.2.1.4.2 5.2.1.4.3 5.2.1.4.4 5.2.1.4.5 5.2.1.5.1 5.2.1.5.2 5.2.1.5.3 5.2.1.5.4 5.2.1.5.5 5.2.1.5.6 5.2.1.5.7 5.2.1.5.8 5.2.1.5.9 5.2.1.5.10 5.2.1.5.11 5.2.1.6 5.2.1.6.1 5.2.1.6.2 5.2.1.6.3 5.2.1.6.4 5.2.1.7 5.2.2 5.2.3 5.2.4 5.2.5 5.3

Initial Operation Normal Operation (Automatic) Manual Operation Current Limiting Overvoltage Control MAINTENANCE AND SERVICE Power Supply Enclosure Chloropac® Control Board Resetting Troubleshooting and Repair Procedures Troubleshooting Charts Voltage Checks POWER SUPPLY DRAWINGS

INLET/OUTLET ASSEMBLIES GENERAL DETAILED DESCRIPTION Inlet Flow Meter Assembly Flow Transmitter Design Principle of Operation Installation Sensor Housing and Transmitter Installation Electrical Wiring Low Flow Limit Switch Relay Contact Setting Contact Wiring Transmitter Operation and control Elements Keypad Description Operation Mode Display Calibration Mode Display Language Engineering Units "K-Factor" Output Current Pulse Output Relay Filter Function Totalizer Test Menu Offset Compensation Span Compensation Frequency Display Flow Simulation Disassembly and Assembly of Flow Transmitter Dispersal Pipe Strainer Circulation Pump Outlet Flow Meter Assembly INLET/OUTLET ASSEMBLIES DRAWINGS


SECTION VI 6.1 6.2 6.2.1 6.2.2 6.3 6.4 6.4.1 6.4.2 6.4.2.1 6.4.2.2 6.4.3 6.5 6.6

SECTION VII

SECTION VIII 8.1 8.1.1 8.1.2 8.1.2.1 8.1.2.2 8.1.3 8.1.4 8.1.4.1 8.1.4.2 8.1.5 8.1.5.1 8.1.5.2 8.1.5.3 8.1.5.4 8.1.5.5 8.1.5.5.1 8.1.5.5.2 8.1.5.5.3 8.1.5.5.4 8.1.5.5.5 8.1.5.5.6 8.2 8.2.1 8.2.2 8.3 8.3.1 8.3.1.1 8.3.1.2 8.3.1.3 8.3.1.4 8.4 8.4.1 8.5

INSTALLATION GENERAL GENERATOR Generator Pipe Connections Dispersal Pipe POWER SUPPLY ELECTRICAL CONNECTIONS Incoming AC Power Wiring Control and Instrumentation Wiring The 120 VAC supply power to the Transmitter electronics The Flow Status signaling by the Transmitter terminal 8 DC Power Wiring INSTALLATION SERVICE INSTALLATION DRAWINGS

SPARE PARTS Spare Parts List

ECP03-000-001 CONTROL PANEL SYSTEM DESCRIPTION AND THEORY OPERATION System Control Panel Overview Theory of Operation System Function -Auto Mode System Function - Manual Mode Specification Controls and Indicators AC Power on Indicator General Failure Alarm Indicator Unit components Power Input and DS-1 Disconnect Switch DLC (Dual Loop controller) PLC (Programmable Logic controller) ORP Analyzer Red Lion Controller Display Menu Screen Alarm Screen Mode Screen System Screen BFA parameter Screen Set Points Screen INSTALLATION Location Wiring TROUBLESHOOTING AND REPAIR Procedures Rosemount Analyzer Programming DLC programming HMI Programming PLC Programming TROUBLESHOOTING CHARTS Voltage Checks MAINTENANCE AND SERVICE

....

''"


SECTION IX 9.1 9.2 9.3 9.3.1 9.3.2 9.4 9.4.1 9.4.2 9.5 9.5.1 9.6 9.6.1 9.6.1.1

DRAWINGS

VENDOR DATA

BIOFOULING FEED BACK ANALYZER MODEL: BFAOOOOO DESCRIPTION SPECIFICATIONS CONTROLS AND INDICATORS BFA Control BFA Indicator INSTALLATION Location Installation Procedure TROUBLESHOOTING AND REPAIR Troubleshooting Charts MAINTENANCE AND SERVICE Repair of BFA Replacing Oxidation-Reduction Potential Probe


1.1

- -/s-I:E cTl·oN-· .. 1

ELECTROLYTIC SODIUM

HYPOCHLORITE GENERATION

DESCRIPTION

Chloropac® system is a trademark of Siemens Water Technologies Electrocatalytic product line for an Electrolytic Sodium Hypochlorite Generator that operates on the principle of electrolysis of seawater.

Chloropac® system, is a system whereby low concentration Sodium Hypochlorite solutions may be generated for constant chlorination needs. Low concentration, constant chlorination has been shown to be more effective then frequent heavy Chlorine dosing. The Chloropac® system output, which eliminates any storage requirement and also the dangers of Liquid Chlorine storage

1.1.2 SYSTEM FUNCTION

The Chloropac® system is basically composed of two principles sections; the Generating Cell and the Power Supply:

Y The Generating Cells are made of inert materials of Polyvinyl Chloride (PVC), Glass Reinforced Polyester (GRP) and Titanium with generating surfaces of Platinum. · ·' ·

Y The Power Supply conve'rts ·higher voltage, lower current AC power to low voltage DC with high current, which passes through the Cells.

Y The Cells are designed to operate at any pressure from 20 PSI to 100 PSI and may discharge to atmospheric pressure or through a Booster Pump into a higher pressure system.

1.1 .3 SYSTEM COMPONENTS

1. Power Supply - This is a power converting device, transforming the Client supplied 380/460 Volts, 50/60 Hz, AC, Input power to a Low Voltage and High Current CONTROLLED DC Output power. This DC power is supplied to the Generator Assembly, to produce the designed Sodium Hypochlorite Output.

2. Generator - Consist of a Cell or a group of Cells arranged in a series path so that the entire seawater passes through each Cell. Because of the Cell configuration, the water sees two sets of generating surfaces in each Cell before it is discharged.

PAGE 1 OF 2


3. Inlet and Outlet Assemblies - Consist of sensing equipment and associated hardware to couple the system to the existing piping system. This option includes Inlet and Outlet Assemblies, Isolation Valves and Dispersal pipes.

1.2 INSTALLATION

Installation requirements are limited to adequate amounts of seawater, electrical power and space. Seawater should be available through a 1 1/a" nominal pipe at

sufficient pressure to supply 25 GPM, and a discharge line 1 1/a", which leads to the point to be chlorinated. Seawater should be a salinity of approximately 20 to 40 ohm-em which is the approximately consistency of sea or coastal salt water. The input lines may be of any suitable sea water resistant material, but the output lines should be of Saran-lined steel, PVC or other corrosion resistant material.

1.3 OPERATION

Chloropac® is designed for constant unattended operation. The Power Supply is of a constant current type, which will provide constant Chlorine Output under changing water conductivity; thus eliminating tidal or temperature induced variances. It is equipped with safety features, which will trip the Output circuits in case of malfunction.

1.4 MAINTENANCE AND SERVICE

There are service and maintenance procedures presented in each of this Manual. However, the equipment has no moving parts and should require little or no maintenance. Anode replating will be required periodically and can be accomplished with a minimum of down time if the procedures in this manual are followed.

PAGE 2 OF 2


SECTION I I

PRINCIPLES OF ELECTROLYTIC

CHLORINE GENERATION

The material presented in this Section has been prepared for the benefit of those who desire to acquire further knowledge of the principles of electrolytic Chlorine generation. It is not necessary to know these principles for the proper installation or operation of the Chloropac® System .

Chlorine is known to be an effective Biofouling control and sterilizant and, as such, finds use in the sewage treatment industry as well as many other applications including drinking water purification, anti-fouling, swimming pools, etc.

Chlorine gas, although economical, is risky to store and use. This is true especially in populated areas where hazards from escaping gas have been documented on numerous occasions.

Anhydrous Liquid Chlorine is a vigorous oxidizing agent that can cause instant autooxidation of a metal surface when ignited by a spark. Water in only a small trace will cause an exothermic reaction, which can cause very rapid corrosion of the metal container. In addition to being a vigorous oxidizing agent and corrosive material, Chlorine gas is classed as a war gas. It is irritant that attacks the mucous membranes of the respiratory tract, the eyes and the skin.

Small amounts of Liquid Chlorine may be released from minor leak in associated equipment. Although they are hazardous to operating personnel, there are safety procedures to use to prevent the majority of these from affecting the general populace. The real problem is considering the catastrophic results of a major failure for which there is no remedial counter-measure.

The release of a 50 ton tank, for example, could require the evacuation of a 5 square mile area. If this were to occur in a highly populated area, it is immediately evident that the results could be disastrous. In order to eliminate the great risk inherent in Chlorine storage and use, many large cities such as New York, Chicago and Providence have shifted to the use of concentrated solution of Sodium Hypochlorite.

Sodium Hypochlorite is available in the concentrated (15%) liquid from manufactured by local companies or made on site where some cities have no local supply available.

Sodium Hypochlorite is the alternate form of Chlorine that comes closes to being economically feasible as a chlorinating agent. In terms of safety, there is no comparison. Sodium Hypochlorite is relatively odorless, and a fresh water flush readily removes any

PAGE 1 OF 10

.,,


residue. There is very little danger in spillage, and no special rules or regulations as required in commercial handling or transporting as compared to the vigorous restrictions imposed on handling or transporting of Liquid Chlorine.

The major reason Sodium Hypochlorite is not more widely used as a chlorinating agent is based on economics. The eight to fifteen percent concentrating does not offset the cost of Sodium Hypochlorite compared to Liquid Chlorine. Other salts such as HTH are in turn several times more costly than Sodium Hypochlorite solutions, thus, they are initially too costly to consider in any large scale operation.

Although the relative safety of Sodium Hypochlorite is well known, it still presents problems because of the large qualities that must be used. For example, a sewage treatment plant using six tons of Chlorine per day requires storage of eighty-three tons of Hypochlorite per day because it is used in concentrations only up to 15% maximum. This also requires transportation and storage of 30,000 tons per year. Transportation and storage costs can be seen as substantial factors in the cost of a liquid Sodium Hypochlorite operation. Large quantities cannot be economically stored because of a short half-life of 100 days at 15% concentration. Some areas do not have a chemical company in the nearby vicinity to manufacture Sodium Hypochlorite and so it is manufactured on the sewage treatment site. This increases dangers because Liquid Chlorine must be used in the manufacturing process.

The obvious solution to the storage and safety problems is to use a system which can produce Sodium Hypochlorite as needed with no storage required. This can be satisfied only with an Electrolytic Hypochlorite Generator.

Siemens Water Technologies' Electrocatalytic product line has perfected a system called Chloropac® system which would fulfill these requirements.

2.1 THEORY OF ELECTROLYSIS

When a current is passed through an electrolyte, the electrolyte is broken down into its constituent elements in accordance with Faraday's Law. Theoretically, one gram equivalent of electrolyte is released for each Faraday of current passed through it. In the case of Chlorine, 35.5 grams are released for 96,500 Ampereseconds of current. This in turn results in one pound of Nascent Chlorine for 343 Ampere-hours of current.

Titanium as an Anode material is ideally suited to this type of operation. It is electrochemically inert at positive voltages of 9 volts or less due to an impenetrable oxide coating. With Platinum plated to a thickness of only 100 micro-inches, this material now becomes a relatively inert electron emitter or Anode which has a consumption rate of only 6 mg of Platinum per Ampere-year. This allows a life of over three years for each 100 microinches plated on the Titanium substrate. (When operated at a current density of 200 Amperes per square foot).

PAGE 2 OF 10


Normally, seven volts is used as the operating voltage between the Anode and the Cathode: however, no current is passed until a voltage of approximately 2.6V is reached. This overvoltage loss is absorbed by the electrolytic reaction of the E I ectro lyte.

2.2

Nascent Chlorine is generated at the Anode and Caustic is generated at the Cathode which reacts to give Sodium Hypochlorite (NaOCI). This is a stable compound of Chlorine. Although this compound can be stored, it is not feasible in low concentrations because of the large volume required. Chlorine in this form is as effective as elemental Chlorine for bacterial and marine growth control without the complications of Liquid Chlorine handling and storage.

EFFECTS OF CHLORINE

Chlorine is a well know toxicant. It has been shown that 0.2 to 0.5 PPM of continuous chlorination will prevent all marine fouling in time. Higher than 0.5 PPM might produce the corrosion of the metallic piping, and other metallic Equipment.

For higher than 0.5 ppm continuous dosing rates please contact Siemens Water Technologies' Electrocatalytic products services for advise.

However, only 0.2 to 0.5 PPM constant dosage is required thereafter to maintain fouling prevention.

It has been the experience of Siemens Water Technologies' Electrocatalytic products that a trace residual discharge will insure the killing of all fouling organisms in a sea water system when constant chlorination is employed.

It should be emphasized that constant chlorination is the best method of safe and efficient fouling and bacterial control.

2.3 SYSTEM SELECTION

The size of the Chloropac® system for any application is dependent upon the volume of water flow and the concentration of Chlorine dosage required.

For a system requiring a normal 0.5 PPM dosage, 0.5 pound of Chlorine will treat 120,000 gallons of water per hour or 2.88 million gallons per day. This will vary according to season, but it is a figure that can be relied upon for fouling prevention.

TABLE 2.1 shows the volume of sea water that can be treated for any capacity of Chloropac® system.

The Chloropac® system units can be added to one another for any desired total output.

Systems may be pressurized or at atmospheric pressure. For atmospheric pressure systems, a minimum of 20 PSI water must be supplied to the Generator and the effluent can be discharged directly to atmospheric pressure. For pressurized

PAGE 3 OF 10

..


systems, the effluent must be discharged to a Booster Pump which will discharge into the pressurized system at a head sufficient to overcome the line pressure.

Concentrations of the Chloropac® system Generator output may be varied based on the flow through or the current supplied to the Generator. Total output of Chlorine is a function of current rather than flow rate, but adequate flow rate is essential for cooling and prevention of calcareous deposit on the generating surfaces. Concentrations of Generator Output are shown in TABLE 2.2 for the Chloropac® system units of various capacities and for various flow rates through the units. A supply of water at 25 GPM is a minimum for safe, long range operation. At flow rates lower than this, provisions for acid cleaning of the internals at regular intervals may be required. Operation at low flow is prevented with Low Flow Safety circuitry. Electrical power requirements for the system are approximately 3 kW/pound of Chlorine. Input requirements are 460 V, 3 phase, 50/60 Hz, with modifications available for other electrical systems.

WATER TREATMENT CAPACITIES

WATER TREATED AT 0.5 PPM CHLOROPAc®CAPACITY lbs/h

GPM GPH

1/2 2,000 120,000

1 4,000 240,000

2 8,000 480,000

4 16,000 960,000

6 24,000 1,440,000

10 40,000 2,400,000

PPM= Parts Per Million: lbs/h =Pounds Per Hour; GPM =Gallons Per Minute; GPH =Gallons Per Hour.

TABLE 2.1

PAGE 4 OF 10


POUNDS PER HOUR OF FREE CHLORINE

Cl2: lbs I hour CHL rating

10

Discharge Concentration in PPM or mg/1

1500 24 40 80 160 240 320 400 800

Normal 1750 29 35 70 140 210 280 350 700

2000 33 30 60 120 180 240 300 600

PAGE 5 OF 10


2.4 GLOSSARY

The terms used in this manual and commonly referred to are listed herein:

Anode

Breakdown Potential

Calcarous Deposit

Cathode

Conductivity

Corrosion

Fouling

GPH

GPM

Nascent Chlorine

PPM

Residual

Resistivity

The surface from which current is passed, and at which Nascent Chlorine is generated. The surface is Platinum coated.

That voltage at which an electrode is no longer passive and goes into solution in form of ions causing damage to the Anode surface.

A gray-white deposit which can appear on Cathode surface due to insufficient flow through the cell.

The surface which receives current in the generating cell. The surface is Titanium.

The opposite of resistivity. It is the ability of sea water in the cell to conduct electricity. It is a measure of reciprocal ohm-em.

The destruction of a metal by chemical or electrochemical reaction with its environment.

Marine organisms, animal, or vegetable, which grow in sea water systems and are considered undesirable from the standpoint of line blockage or preventing adequate heat transfer.

US Gallons per hour.

US Gallons per minute.

Element Chlorine which is generated at the Anode surface and combines with caustic generated at the Cathode surface to form Sodium Hypochlorite.

Parts per million by weight.

The concentration of Chlorine rema1nmg after it has passed through the area to be chlorinated. It is a measure of the unconsumed Chlorine.

The electrical resistance as seen by the systems caused by sea water in the cells. This fluctuates with salinity and temperature. It is measured in ohm-em.

PAGE 6 OF 10


2.5 GAS ELIMINATION

1.

2.

3.

4.

2.6

The electrolysis of sea water releases Hydrogen in a volume approximately equivalent to the gaseous Chlorine available from the Sodium Hypochlorite. The Hydrogen is sparingly soluble in water and must be removed where its presence is not tolerable. When the Hypochlorite discharge is applied to well-ventilated open water, such as uncovered holding tanks, troughs, or desalination inlets, special gas venting is generally not necessary. The accumulation of sufficient quantities of Hydrogen gas in confined areas can cause a fire or explosive hazard, however, means should be provided to release the gas. The appropriate gas venting method is determined by the circumstances of usage. There are several choices available to the customer, all of which are completely safe and accepted by the industry:

Vent the gas to the atmosphere where either the volume of the Hydrogen and/or the free exposure provided at the location eliminates the problem.

Provide continuous forced draft ventilation at the location to sweep away the Hydrogen

Where the Sodium Hypochlorite is ingested directly into a pressurized pipe, the Flow Through the pipe is usually adequate to carry the gas bubbles away without danger of gas accumulation within the pipe (but the piping system should be inspected to confirm this).

A small temporary storage tank for the venting of Hydrogen flow before being pumped into the system.

Gas elimination equipment is optional with the buyer. The specific type of equipment which best suits an installation can be determined by either Siemens Water Technologies' Electrocatalytic products or the buying installation, but in either case, the responsibility for adequacy of the equipment lies with the Buyer. Hydrogen elimination is a normal procedure for equipment of this type. Hydrogen can be handled safely with proper precautions. No Smoking, welding or open flames should be permitted where Hydrogen may be present.

WATER QUALITY AND PERFORMANCE

The unique Chloropac® system Cell configuration is designed to operate in a wide range of sea water temperatures and total dissolved solids (TDS) concentrations.

Continuous long term operation without back-flushing or acid cleaning is achieved by the straight through design and turbulent flow.

Operating Cells have accumulated in excess of 100,000 hours combined operation without requiring shutdown for maintenance or cleaning.

PAGE 7 OF 10

•

""


The typical sea water analysis, listed in TABLE 2.3, shows the high concentration of hardness (Calcium and Magnesium) that the Cell is designed to encounter in normal operation.

The Graph in FIGURE 2.1 (at the end of this Section) presents the relationship between water total dissolved solids and resistivity (conductivity) as a function of temperature.

Included on the Graph are design lines for the standard, normal sea water (30 ohmem), and standard brackish water, (60 ohm-em) Chloropac® Generator system. System direct current Power Supplies are also manufactured for warm sea water (20 ohm-em) and cold seawater (36 ohm-em) applications where water resistivity ranges are limited.

PAGE 8 OF 10


NOMINAL COMPOSITION OF SEA WATER COMMON NAME SYMBOL Mg/L (PPM) Chloride Cl 19,350 Sodium Na 10,750 Sulfate S04 2,700 Magnesium Mg 1,290 Calcium Ca 410 Potassium K 380 Bicarbonate HC03 140 Bromide Br 65 Strontium Sr 13 Aluminum AI 1.9 Silicon Si 1 .1 Fluoride F 0.8 Nitrate N03 0.8 Boron B 0.4 Barium Ba 0.2 Iron Fe 0.2 Manganese Mn 0.2 Copper Cu 0.1 Lithium Li 0.1 Phosphorous p 0.06 Iodide I 0.04 Silver Ag 0.02 Arsenic As <0.01 Nitrite No2 <0.01 Zinc Zn <0.01 Total Mg/L (PPM) 35,000 (excluding Hand 0)

... 2.7 GRAPHICS I DRAWINGS

""''' PAGE 9 OF 10

SIEMENS Section Principles of Electrolytic Chlorine Generation

S' u I

:::::;:

0

20

25

6 30 -

0

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fl '-H-f-- f- ELECTRICAL RESISTIVITY (CONDUCTIVITY) f- f- OF f-~ SEAWATER

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STJ b~~ ~rc 1/ f--f--:::!!

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Water Technologies

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30 40 TOTAL DISSOLVED SOUDS (TDS) g/1

FIGURE 2-1

SEAWATER RESISTIVITY

PAGE 10 OF 10


SECTION I I I

CHLOROPAC® SYSTEM GENERATOR

3.1 DESCRIPTION

The generating Cells of the Chloropac® system are manufactured of completely corrosion resistant metals and plastics. (See Chart at end of Section Ill).

The electrodes are manufactured of metallurgical grade Titanium and are used as generating surfaces and pressure containers concurrently. Each Cell has one Inner and two Outer Electrodes which are electrically separated by the union bodies (see FIGURE 3-1 at the end of this Section). The Positive side or Anode of each Cell is Platinum plated which enables the Cell to pass a current. Titanium is passive at the Positive voltages which the system operates (7 volts) and is used un-plated as the Negative Electrode or Cathode.

The sea water passes between the Inner and Outer shell and enables a current to flow. The current dissociates the sea water into its basic elements which re-act to form the Sodium Hypochlorite which is the compound transmitted for later release of its Oxygen.

The water passes successively through a series of identical Cells. For example, from four 1 lb/h rated Cells connected in series, one pound of equivalent Chlorine is produced with a current of 450 Amperes at a rated flow of 25 gallons per minute by the first Cell, and another one lb/h is produced by the second Cell, etc., for a total production of four lbs/h of equivalent Chlorine.

The Cells are designed for trouble-free operation if the design criterion for their operation is met. A minimum flow of 25 gallons per minute of sea water should be maintained to eliminate the buildup of any deposits on the generating surfaces. The system will operate at flows below 25 GPM, but procedures for acid cleaning which are outlined in the Maintenance portion of this Section may need to be followed to insure trouble-free operation. If system will operate with flow rates below 25 GPM, the Low Flow Switch will automatically cut the DC input power to the Sodium Hypochlorite Generator.

In some units over 4 pound per hour capacity, the Cells are wired in series-parallel arrangement with two or more Cells in series and two series wired in parallel. This configuration enables the system to be wired with the Positive feed in the center and the Negative or ground lead at each end of the system.

This allows the Inlet and Outlet to be at the same potential and eliminates any external (stray) current flow due to potential differences. The Cells do operate at different potentials, however, and care must be taken to avoid contact with any two

PAGE 1 OF 8

...


cells as potentials of 28 volts and current flows of 450 Amperes can be experienced. (Total voltage potentials up to 42 volts and 450 Amperes are developed depending on system size).

3.2 INSTALLATION

Chloropac® system is shipped as two units, the Generator and the Power Supply.

The Power Supply is wall mounted in an area of approximately 32" H x 29" W x 17" D (with a door swinging area of 26" in front of the enclosure).

The Generator is floor or deck mounted in an area 58"L x 15"W x 18"H.

Installation requirements are 25 GPM at 40-50 PSI minimum delivered to the Inlet point of the Generator through a 1-1/2" nominal pipe with a stop Valve in-stalled, and a 1-1/2" nom ina! pipe for discharge, installed to the delivery point with a stop Valve at the Generator outlet side. Water should be of sea water consistency of approximately 20 to 40, ohm-em resistivity.

The Generator and the Power Supply should be located as close to each other as possible to keep the voltage drop between the two to a minimum. See Section 4.2.2 for cable sizes required with increase in distance.

3.3 OPERATION

Chloropac® system consists of two major components the Power Supply and the Generator:

};> The Power Supply converts ACto DC power

};> The Generator takes the DC current and utilizes it to generate Hypochlorite

The Chlorine output of the system is direct function of current input to the Cells. The Power Supply is a constant current device and will drive the voltage higher or lower, dependent on the resistance of the circuit including the resistivity of the sea water passing through the Cells. If tidal conditions cause brackish water to pass through the Cells, the voltage will go higher (and may cause, if installed, a high voltage alarm; see Section 3.4.2).

The current through the Cell will determine the amount of Chlorine being generated by the system. The concentration of Chlorine may be determined with a test kit by using a sample from the test point. Concentration alone will not give Chlorine output because it is a function of the amount of water flowing through the unit.

For flow conditions other than the normal 25 GPM, the concentration desired or the total output can be determined from TABLE 2.2 (Section II, Page 5) knowing the flow through the unit.

PAGE20F8


For example, at 25 GPM, a 1 pound per hour injection rate will yield a concentration of 80 PPM, or 40 PPM for 1/2 pound per hour injection rate.

If full output is not desired from the unit for any reason, the current can be decreased to any level with the CURRENT LIMIT control knob. The current rating for each one lb/h Cell is one lb for 450 Amperes, thus total output can easily be interpreted from the Ampere meter.


Since the Chloropac® system is basically very simple, incorporating no moving parts, reliability of the system is assured and maintenance is reduced to a mini-mum. As long as the unit is operated in accordance with the standard accepted operating practices, it should remain practically trouble free. Preventive maintenance requirements are met by making the periodic checks and taking the readings as shown on the Chloropac® system OPERATING LOG Sheet at the end of this Section. Corrective maintenance procedures will ordinarily be con-fined to the Flow switch, stopping leaks, correcting generating Cell problems or electrical problems.

When completed at the end of each month, A SIGNED COPY of the OPERATING LOG Sheet must be mailed or faxed to Siemens Water Technologies' Electrocatalytic Product for filing, and future service reference.

3.4.1 LEAKS

The most likely area for leaks is around threaded connections, around the "0" rings in the Cells, or around the mating flanges. Unless the connection has worked loose, tightening the connection is usually not advisable since there is danger of overtightening the connection and damaging the plastic fittings. It is normally sufficient to disassemble the leaking connection, thoroughly clean all parts inspecting for nicks or damage, renew the "0" ring, gasket or Teflon tape as applicable and replace the connection. When replacing threaded connections, a few turns of Teflon tape will normally insure a leak-free connection.

When replacing a Generator Cell connection the PVC nuts should be hand tightened onto the Unions, then tightened one and one quarter turns more using an Adjustable Spanner Wrench (SWT part number 56337). When replacing an "0" ring it should be re-torqued in about 8 hours to take up on slack caused by the Teflon cold flow.

3.4.2 HIGH VOLTAGE

PAGE30F8

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...

'""


The high voltage alarm, if installed, comes on in any Cell or Group of Cells; it is indicating a situation which is potentially very damaging. High voltage (over 9V per 1/2 Cell) may cause the Titanium in the Cell to corrode and thus permanently damage the Cell. It can be caused by several situations. If more than one Cell or all Cells experience high voltage simultaneously, it is likely that fresh water has entered the Cells in sufficient quantities to cause the resistivity of the water to increase significantly.

Loss of Platinum on the Anode surface will also cause high voltage. All Anode materials are consumed even though they may be classified as inert. Platinum has a consumption rate of 6 mg/Amp year and, at that rate, with a 200 micro inch coating, the Anode has a life of 4 to 6 years. The only solution to this is replating of the Platinum which must be done at the factory. This can be done at moderate cost and in a short period of time.

It is usually prudent to send all Cells for replating at the same time to eliminate as much down time as possible. An alternative would be to carry a number of spares and program the replating.

High voltage can also be caused by a faulty power lead connection at the Cell. This can cause a high resistance joint and an increase in voltage and temperature. This may be caused by moisture producing corrosion products on the terminal lug or on the copper bus. This can be eliminated by complete cleaning of the connection assembly and making watertight with a plastic spray and covering with plastic tape.

3.4.3 EXCESSIVE PRESSURE DROP

Excessive pressure drop or decrease in flow can be caused by a blockage in the system, either external or internal to the Generator. The most common type internal blockage is caused by calcareous deposits at the Cathode surfaces. This deposit is a soft, thick white paste type deposit which when exposed to air will dry to a hard crystal. These deposits generally result from chronic low flow conditions.

Wet deposits can ordinarily be removed by disassembling the Generator unit and hosing down the Cell parts with high pressure water. Dry, calcified deposits may be removed by disassembling the unit and soaking the Cell parts for 16 hours in a 5% (by weight) solution of Acetic Acid followed by a thorough rinsing in water fore reassembly. Replace all resilient seals every re-assembly.

PAGE40F8


3.4.4 FLOW METER

The Flow Meter with low flow contacts is provided to trip the AC contactor if the water flow through the Cells should stop or be reduced to less then approximately 25 GPM. Monthly checks of the Flow Meter should be preformed and the results recorded on the log sheet. The Flow Meter can be tested as outlined in Paragraph 5.2.1 (Flow Meters).

If the Digital Display fails to respond or indicates low GPM when flow is either shut off or resumed, the open-cell Paddle-Wheel within the Sensor may be clogged with debris, and should be cleaned.

The Flow Meter is calibrated to the size of the pipe and set at the factory to show low flow below 25 GPM. Maintenance on the Meter is mainly on frequent checking for proper operation. Checking daily is desirable, but weekly is more practical. All aspects of the Flow Meter are covered in Paragraph 5.2.1.

If the Flow Meter fails to operate, it is for one or more of the following reasons:

1. Inadequate flow not reaching the "Paddle Wheel Sensor";

2.

3.

The "K" Factor on the Flow Meter should be checked to insure the correct calibration is keyed in (See Table 5.1 "K" -Factor based on Pipe Size and Material);

Check the AC voltage which powers the Flow Meter (115 VAC required);

3.4.5 DISASSEMBLY AND ASSEMBLY OF THE GENERATOR (Refer to FIGURE 3-1 at the end of this Section)

1.

2.

3.

Remove all power to the Generator by turning the Power Supply's Main Circuit Breaker or Main Disconnect Switch "OFF";

Remove the cover or doors from the Generator;

Disconnect the DC cables or bus bars from the Cell to be removed; Label the cable or bus bars so that they can be connected correctly during reassembly;

4. Remove the polypropylene tubing from the Cell if present;

5. Loosen the outer most PVC nuts at each end of the Cell by turning them counter-clockwise with the Adjustable Spanner Wrench (Eiectrocatalytic Part Number 56337). Remove the elbows, inlet, or outlet piping from each end of the Cell Assembly. Use Spanner Wrench to hold the union while loosening the nut;

PAGE 5 OF 8

...

•

...

...

...


6. Remove the "U" bolts from each end of the Cell;

7. Remove the Cell;

8. Disassemble the Cell as follows (using the exploded Cell view in FIGURE 3-1 as a reference);

a. Loosen the PVC nuts (item 9) at each end of the Cell and remove the pinned unions (items 5 and or 6) and stub ends (item 11 );

b. Remove the cone spacers (item 1 0) from both ends of the Inner Shell;

c. Carefully remove the Inner Shell (item 3) from the other shells (items 1 and 2);

d. Disassemble the center Assembly by undoing the two PVC nuts (item 9) and stub ends (item 11 ). Separate both Outer Shells (items 1 and 2) from the plain union (item 4);

9. Assemble the Cells as follows (FIGURE 3- 1 as a reference):

a. Clean the "0"-ring groves and replace all the "0"-rings;

b. Connect the plain union (item 4) with the Outer Shell Anode and Cathode items 1 and 2). Place the stub ends (item 11) in position over the Outer Shell and tighten the PVC nuts (item 9) by turning them clockwise. The PVC nuts should be hand tighten then turned an additional 1 1/4 turn more with an Adjustable Spanner Wrench (Electrocatalytic Part Number 56337);

c. NOTE: The Outer Shell will be identified with a serial number stamped at one end.

d. Insert the Inner Shell (item 3) and be certain that the serial numbers on the Inner Shells are aligned on the same end of the Cell;

e. NOTE: ORIENTATION IS CRITICAL.

f. With the serial numbers at the same end of the Cell, there will be an

g. Anode (plated Cell surface) opposite a Cathode (unplated Cell surface) which is the correct Assembly.

h. Install the cone spacers (item 1 0) into both ends of the Inner Shell;

i. Install the pinned unions (items 5 and 6) at each end of the Shell. Place the stub ends (item 11) in position over the other Shell and tighten the

PAGE60F8


PVC nuts (item 9). The PVC nuts should be hand tightened then turned an additional 1 - 1/4 turns more with an Adjustable Spanner Wrench;

10. Re-install the Cell in the Generator Assembly;

11. Tighten the Outer most PVC nuts at each end of the Cell by turning them clockwise with the Adjustable Spanner Wrench. Reattach the elbows, Inlet or Outlet piping from each end of the Cell Assembly. The PVC nuts should be hand tightened then turn an additional 1 1/4 turns with an Adjustable Spanner Wrench. Use second Spanner Wrench to hold the union while loosening the nut;

12. Re-install the "U" bolts at each end of the Cell;

13. Re-attach the polypropylene tubing to the Cell if present;

14. Re-connect the DC cables or bus bars to the Cell. Check the labels on the cable or bus bars so that they are connected correctly during reassembly;

15.

16.

17.

Re-establish sea water flow through the Cells. Inspect the Generator for leaks;

Return power to the Generator by turning "ON" the power to the Power Supply. Inspect the Generator for leaks and proper electrical operation. Take and measure a Sodium Hypochlorite sample and compare to expected output;

Re-install the cover or doors to the Generator.

PAGE70F8

..,


CORROSION RESISTANT MATERIALS ~

SYSTEM COMPONENT MATERIAL SPECIFICATION

Generating Cell Titanium ASTM 8-338-GR2

Cell Coating Platinum Alloy El ALLOY No. 63545-s

Process to S-53901

Cell Centering Pin Titanium ASTM 8-265-GR2

Cell Spacers CPVC ASTM D-1784-2344 78

"0" Rings Teflon ASTM D-2000

Split Stub End CPVC ASTM D-1784-234478

Union CPVC ASTM D-1784-234478

Union Nuts CPVC ASTM D-1784-234478

Piping and Valves CPVC ASTM D-1784-234478

Power Supply Enclosure Steel ASTM A-37 & A-527

Painted Steel Enamel MII-E-15990

Non-Wetted Hardware Stainless Steel ANSI-316

Generator Case Stainless Steel ANSI-304

NOTE: Other coating systems available.

TABLE 3-1

3.5 GENERATOR CELL DRAWINGS

PAGE 8 OF 8

' '

Section Ill 4 lbs/h Generators using 1 lb/h Cell PN: 50669-002-M

--IE::::

-------------------1--3.520 -1------------------

I 429~6" ----------------------------------------------------~

~

FIGURE 3-1

lb/h Sodium Hypochlorite Generating Cell

For ELECTROCATALYTIC Part Number see TABLE 7-2

For Assembly Sequence see Section 3.4.5

I • I ' I I I I I I ' f I I ' ' ' r ' ' ~ I i '

3

f ~ t '

DESIGN AND REEFRfNCE DATA

INPUT VOLTAGE: 26-28VOC, 0-450ADC SEAWATER FLOW RAT£: 20-32gpm 0 25-100psl

CAPACITY: 41b/h MAX SODIUM HYPOCHLORITE 0 LOAD RATINGS OF 28Vt>C, 450ADC IN SEAWATER

TEMPERATURE: 0-SS'C CONSlRUCTlON: DECK MOUNTED ENCLOSURE 304-SS

= 1. (1) VOLT MAX DROP ACCROSS WIRE LENGTI-1 PER LEAD.

CENTER OF GRAVITY WEIGHT~ 2701b [122.7kg]

11lj" [460]

OUlLET

1-1/2"[38] 150LB ~ ANSI F.F.

FLANGE (TYP)

r [19]

,.. [<57]

L '--------' ljl ~ lQ,QJ I - ~'"'-CUSTOMER I s d-v---- ACCESS PANEL

26 24 22 20 18

gpm~! 12 10 • •

41b/h GENERATOR

PRESSURE DROP 25gpm • 8.6psl

1234567 Bto

psi (OPERATING AT FULL OUTPUT)


SECTION IV

CHLOROPAC® CONTROLLED SWITCHING

POWER SUPPLY MODEL 50682-004SW-02/-04, 4 LBS/H, IP-23/IP-44

Note that more than one Model of Power Supply may be supplied for this ship or structure. Various Power Supplies may be similar in appearance but different in construction, amperage rating and operation. Ensure that you are using instructions for the Power Supply installed.

4.1 DESCRIPTION

The purpose of the Chloropac® Controlled Switching Power Supply is to continuously maintain a preset level of Sodium Hypochlorite output under changing water conditions.

The Power Supply is of switching power type. The circuitry consists mainly of a three phase (EMI) Filter, a three phase Full Wave Diode Bridge (D3), Capacitors (C1 thru C6), Insulated Gate Bipolar Transistor (IGBT, Q1 and Q2), Commutation circuit, a High Frequency step-down Transformer (T1) followed by a Rectifier circuit made of a Full Wave Diode Bridge (D1 and D2), a DC smoothing Inductor (11) and Capacitors (C7, C8, C9 and C1 0) that supply a Fused DC (Amps and Volts) Output to a DC bus.

The CHLOROPACV Control (CC Board) control signal is applied to the input of the Pulse Width Modulation (PWM Board) control circuit. The PWM control circuit varies the pulse width of the signal used to drive the IGBT driver circuits.

The unit is provided with an "AUTO/MANUAL" Selector Switch (SW1) and several Operators located on the Power Supply door, accessible from the outside of the Enclosure.

With the Selector Switch SW1 in MANUAL position, the "MANUAL ADJUST" Potentiometer located on the control panel door permits the unit to be set to a CONSTANT DC OUTPUT, thus maintaining a Unique/preset CHLORINE RESIDUAL during the INSTALLATION and TESTING of the unit.

Some Automatic Features are defeated during operation within this Mode.

NOTE: THIS OPERATION MODE SHOULD BE USED ONLY FOR A TEMPORARY I --TESTING PERIOD, AND ONLY WHEN THE NORMAL WATER FLOW IS PRESENT AND THE GENERATOR DOES NOT INDICATE A LEAK CONDITION.

PAGE 1 OF 24

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With the Selector Switch (SW1) in AUTOMATIC position, the controlling circuitry permits the unit to:

A. AUTOMATICALLY change the DC OUTPUT (Amps and Volts) based on aremote control signal (0 to 20 mA, 4 to 20 mA, 0 to 10 V DC or 2 to 10 V DC across a 500 ohms 1%, input load resistor) from a remote computer;

B. AUTOMATICALLY change the DC OUTPUT based on the number and the size of the simultaneously running pumps;

C. TRIP when a "LOW SEAWATER FLOW" or "GENERATOR LEAK" condition is detected, etc.

The flowing devices are located on the front of the Power Supply:

Meters:

1. AM1: DC CURRENT Output:

2. VM1: DC VOLTAGE Output:

Indicating Lights, performing the following functions, when "ON":

3. White Light LT1 "POWER ON" indicates the AC Power available to the unit:

4. Red Light LT2 "GENERAL ALARM" indicates trouble in the rectifying stages of the unit:

5. Red Light LT5" LOW FLOW" indicates a flow of 25 GPM or higher;

6. Green Light LT4" NORMAL FLOW" indicates a flow of 25 GPM or highter:

7. Red Light LT3 "GENERATOR LEAK" indicates a water leak within the Generator.

Operator:

8. "AUTO I MANUAL" Selector Switch (SW1) to switch between the two operating Modes;

9. "Manual ADJUST" Potentiometer (R2) to vary the DC OUTPUT, in Manual Mode between 0% and 1 00% of Rated Output.

10. "CURRENT LIMIT ADJUST" Potentiometer (R1) to limit the high value of the DC Current Output, depending on the type of the Sodium Hypochlorite Generator used.

PAGE 2 OF 24


"LEAK RESET" Push-button (PB1) to reset the Power Supply after automatically shutting down on a "Generator Leak" detected condition:

11.

12. "MAIN POWER" Disconnect Switch (DS1 ), to turn the power "ON" and "OFF", and allow for the opening of the Enclosure Door.

4.1.1 SPECIFICATIONS

Input Voltage 460 V AC (or 380 V AC as supplied). 50/60 Hz. 3-Phase, 3-Wire, and Grounding

Power 0.10 kVA to 4.16 kVA at 28 V DC. Requirements:

Input Main Fuses: 3 Pieces, 30 Amps each, 1 0,000 A/C.

Unit operates +/-1 0% Voltage variation, +I- 5% Frequency variation. with:

Output: 450 A DC@ 28 V CD at 50° C (122° F) ambient temperature, 12.60 kW DC /3.26 k WAC at 28 V DC.

Control Range: A 0-to-10 V DC (2-to-1 0 V DC) Control Voltage, or a 0-to-20 mA (4-to-20 mA) Control Current produces full Output from 0 to 100% of Rated Value.

Controlling Transistorized amplifier board driving two pairs of IGBT's method: connected to step-down Transformer. A Full Wave Entour tapped

rectifier furnishes DC voltage to the Sodium Hypochlorite Generator Cells.

A Full Wave entour ta(;1(;1ed rectifier furnishes DC voltage to the Sodium HyQochlorite Generator Cells.

CONSTRUCTION: General use (IP-23) or Splash-proof (IP-44) as specified, bulkhead mounted enclosure, with blue enamel finish (Munsell Color 7.5 BG 7/2).

DIMENSIONS: See Installation Drawing for Power Supply in Section VI. Enclosure is 32" H (813 mm) x 29" W (735 mm) x 16" D (406 mm) overall, with 4 mounting holes of 9/16" (14mm) diameter for bulkhead mounting on 20" H (508 mm) x 27" W (686 mm) centers.

The 26" W (660 mm) Front door swings clockwise about 120 degrees.

WEIGHT: @ 200 lbs. (83 kg) for 130 A DC/14 V DC unit

PAGE 3 OF 24

"'

...


@ 245 lbs. (114 kg) for 45a ADC/28 V DC unit

OPERATING Maximum sao C internal rise at 55° C ambient. TEMPERATURE:

4.2 INSTALLATION

4.2.1 LOCATION

The Power Supply should be located as near to the Sodium Hypochlorite Generator as possible, and in a location protected from the weather. The following factors should be considered in selecting a suitable mounting place:

1. The air temperature should not exceed sao C (122° F):

2. A bulkhead or wall mounting at eye level permits easier and more accurate

3. The mounting location should be reasonably accessible with adequate clearance for door opening (the 26" wide door swings about 12a degrees), and protected from direct water spray or rising steam;

4. The mounting location should have adequate clearance between the Enclosure sides/top/bottom and any obstruction which will prevent the free cooling air circulation.

4.2.2 WIRING

The CHLOROPAc® System interconnecting wiring is shown in detail in the Section VI, Paragraph 6.4 (Electrical Connections), and in the associated Installation Drawings.

4.3 OPERATION

Prior to operation, check all wiring to ensure Incoming AC Power Feeder, the Positive and Negative Power Leads, the Grounding wire, and control wires are correctly connected to their respective terminals on the Power Supply and/or the Generator.

4.3.1 THEORY OF OPERATION

As detailed in Section II (Principles of Electrolytic Chlorine Generation) of this Manual, the amount of the Sodium Hypochlorite produced is directly proportional with the amount of the DC Current being circulated through the Generator's sea water.

To keep a CONSTANT DOSING of the Sodium Hypochlorite it is required to maintain a CONSTANT LEVEL of the DC CURRENT.

PAGE 4 OF 24


This Switching Power Supply is a CURRENT AMPLIFIER type. Once a certain DC Output Current is selected, the unit will try to keep a CONSTANT DC Output Current through the Output Load, which is made of the Generator Cells, and the resistivity of the sea water circulating through the Generator.

The resistivity/salinity of the sea water will vary depending on the location of the Ship I Vessel (brackish water, fresh/river water, etc). The DC Output Voltage applied across the Generator/load terminals will vary accordingly, based on the total Load resistivity. A nonconductive (or less conductive) sea water will require a larger than normal DC Output Voltage.

To prevent the damage to the Generating Cells, this DC Voltage MUST BE LIMITED to a safe value.

When the Voltage Limiting circuitry begins to react, the DC Output Current is being feedback I decreased, to maintain the Maximum/High Voltage Limit.

(See Paragraph 4.3.8 for detailed description).

4.3.2 UNIT COMPONENTS

4.3.2.2 Power Input and EMI Filter

NOTE: If the input power is 380 VAC, then the tap on Transformer T3 must be changed from 460 VAC to 380 VAC.

The CHLOROPAc® Switching Power Supply receives 460 V AC (or 380 V AC as supplied by the Client), 3-Phase, 50/60 Hz, power through Main Disconnect Switch (DS1), and Main AC Fuses (F1, F2, F3). Surge suppressors (SA 1, SA2, SA3) provide protection against power surges in the input power. The power is Filtered/Conditioned through an EMI (Electro-Magnetic Interference) Filter, capable to reduce the level of the noise created by the 14 kHz Power Switching.

4.3.2.3 Bridge Rectifier (03) and Power Transformer (T1) Primary

A Three-Phase Full Wave Diode Bridge Rectifier (D3) (Rated 1600 Volts, 60 Amps) in an isolated Module rectifies the AC Input Power, and generates a 600 V DC bus voltage across IGBT's (Q1) and (Q2). A set of Capacitors ECL2 (C1, C2, C3 and C4) plus Capacitors (CS) and (C6) condition the Filter DC Output.

4.3.2.4 Control Transformer (T3)

The Input Voltage is reduced by the Control Transformer (T3) to 120 V AC, Single Phase, to provide control power to:

1. (PC1 ): PULSE WIDTH MODULATION BOARD -PWMB-;

2. (PC2): CHLOROPAC® CONTROL BOARD -CCB-;

PAGE 5 OF 24


(PC3) and (PC4): ISOLATED GATE BIPOLAR TRANSISTORS -IGBT- drivers; 3.

4. Heat Sink and cabinet Cooling Fans;

5. Sodium Hypochlorite Generator FLOW METER electronics.

When the Main Disconnect Switch (DS1) is turned "ON", 120 V AC power from the Control Transformer (T3) through Fuse (F4) is supplied to all of the above components, and the "Power ON" Light (LT1) illuminates.

4.3.2.5 Pulse Width Modulation (PWM) control and IGBT Drivers

When the "AUTO/MANUAL" Selector Switch (SW1) is in "AUTO" position, the output signal voltage from CCB (PC2) controller is used to control Power Supply Output.

The CCB control signal is applied to the input of the Pulse Width Modulation (PWMB) control circuit (PC1) at J7-4. The PWM control circuit varies the pulse width signal used to drive the IGBT driver circuits (PC3 and PC4). The IGBT driver circuits turn the IGBT's (Q1 and Q2) "ON" and "OFF" as required. The IGBT transistor commutation circuits house Transistors which commutate the primary of the high frequency step-down Transformer (T1) with a DC square wave of variable pulse width at 14kHz.

4.3.2.6 Manual Control

When the unit "AUTO/MANUAL" Switch (SW1) is in MANUAL position, the control signal to the PWM Board (PC1) is adjustable manually through "MANUAL ADJUST" Potentiometer (R2), and the automatic functions of the CCB are disabled.

The manually controlled signal is fed to the pulse width modulation circuit which functions to provide a signal to the IGBT (PC3 and PC4) drivers as above. The PWM control also provides the functions for setting the CURRENT LIMIT ADJUST Potentiometer (R1 ).

4.3.2.7 Power Transformer (T1) Secondary and DC Output

The secondary of the High Frequency Step-Down Transformer (T1) is followed by a Rectifier circuit (D1 and D2), a DC smoothing Inductor (11) and Capacitors (C7-C1 0). The secondary of the Transformer is rectified by the output power Diodes (D1 and D2) to Low Voltage and High Current DC. The output Inductor (11) and Capacitors smooth the output DC for minimal Ripple Voltage and Current. The output Current Sensor (J1) provides FEEDBACK input to the PWM control for Power Supply output reference.

4.3.2.8 Main Disconnect (DS1) and Main AC Fuses (F1, F2, F3)

The Switching Power Supply is provided with protection against the Short-circuit and Over-current.

PAGE 6 OF 24


1. The 460 V AC (or 380 V AC) Incoming Feeder is connected to the Main Disconnect Switch (DS1 ), Terminals A, B, C (and GND if the Feeder has the Equipment Grounding Conductor wire). Internally, from the DS1, the AC Power is routed to the Main AC Power Fuses (F1, F2, F3). The 500 V AC, Slow Blow, Rated Fuses have a Short Circuit Interrupting Capacity of 1 0,000 A. The protecting Fuse sizes for each rated Switching Power Supply are shown in Section VI, TABLE 6.1.

2. The Control Transformer (T3) is protected on the Primary Side by a Fuse (F4), type FNQ-2, 2 Amps, 500 V AC, Slow Blow.

3. The Sodium Hypochlorite Generator is protected on the POSITIVE Side by GOULD SHAWMUT Semiconductor Fuses, rated 130 V AC/DC. The Fuse capacity must match the Generator DC Output Rating, as shown in TABLE 4-2 (Fuse Replacement Chart) at the end of this Section.

4.3.2.9 Operators, Indicating Lights I LED's and DIP Switches

1.

2.

3.

4.

5.

6.

7.

8.

A. Located on the Enclosure Cover:

Five Indicating Lights are furnished on the front of the Power Supply, performing the following functions, when "ON":

"POWER ON" (LT1), White Light, indicates the AC Power available to the unit;

"GENERAL ALARM" (LT2), Red Light, indicates trouble in the rectifying stages of the unit;

"LOW FLOW" (LT5), Red Light, indicates a flow lower than 25 GPM through the

Sodium Hypochlorite Generator Cells;

"NORMAL FLOW" (LT4), Green Light, indicates a flow of 25 GPM or higher;

"GENERATOR LEAK" (LT3), Red Light, indicates a water leak within the Generator.

Five Operators are furnished on the front of the Power Supply, performing the

following functions:

"AUTO/MANUAL" Selector Switch (SW1) to switch between the two operating

Modes;

"MANUAL ADJUST" Potentiometer (R2) to vary the DC OUTPUT, in Manual Mode,

between 0% and 1 00 %of Rated Output;

"CURRENT LIMIT ADJUST" Potentiometer (R1) to limit the high value of the DC

Current Output, depending on the type of the Sodium Hypochlorite Generator

used;

PAGE 7 OF 24

..


"LEAK RESET" Push-button (PB1) to reset the Power Supply after automatically 9.

shutting down on a Generator leak detected condition;

10. "MAIN POWER" Disconnect Switch (DS1) to turn the Incoming Power "ON" and

"OFF";

Two Meters are furnished on the front of the Power Supply, performing the

following functions.

11. "OUTPUT CURRENT" (AM1) Amperemeter, to display the DC Amps Output;

12. "OUTPUT VOLTAGE" (VM1) Voltmeter, to display the DC Volts Output.

1. 2. 3. 4. 5. 6.

7. 8. 9.

1. 2. 3.

4.

5. 6.

7. 8. 9.

10.

B. Located on the PC1 (PWMBoard):

c.

a.

(LED1 ), Green, indicating the presence of(+) 15 VDC on the Board; (LED2), Green, indicating the presence of(-) 15 VDC on the Board; (LED3), Yellow, indicating the Unit is in "OUTPUT CURRENT LIMIT" Mode; (LED4), Yellow, indicating the Unit is in "OUTPUT VOLTAGE LIMIT" Mode; (LED6), Red, indicating the Unit is in "SHORT CIRCUIT TRIP'' Mode; (LED7), Red, indicating the Unit is in "IGBT FAULT" Mode: (When this LED is lit, the Board Alarm Relay (K1) will annunciate the Fault) (LED8), Red, indicating the Unit is in "OVER TEMPERATURE TRIP" Mode; (R1 ), Trimmer, 1 0-Turn, to adjust the Range of the Current Limit; (R2), Trimmer, 1 0-Turn, to adjust the Range of the Voltage Limit;

Located on the PC2 (CCBoard):

(LED1 ), Green, indicating the presence of(+) 15 VDC on the Board; (LED2), Green, indicating the presence of(-) 15 VDC on the Board; (R1, 2, 3 and 4), Trimmers, to adjust the Value/Percentage of each individual Pump Flow in reference to the TOTAL Required Flow; (Pump No. 1 Percentageof-Total Flow+ Pump No.2+ Pump No.3+ Pump No.4= 1 00%). (R34), Trimmer, to adjust the Value of the Input Signal OFFSET; (e.g. 0 or 4 to 20 mA, 0 or 2 to 10 V DC). (R39), Trimmer, to adjust the Input Signal GAIN to the Comparator Amplifier; (R45), Trimmer, to adjust the Output Current Feedback Signal GAIN to the Comparator Amplifier; (R49), Trimmer, to adjust the GAIN of the Board Output Transistor (Q3); (R70), Trimmer, to add an OFFSET Signal to the Comparator Amplifier; (R74), Trimmer, to simulate an Output Current Feedback Signal, needed to setup the Board; (DS1 ), DIP Switch, 7-Positions, needed to setup the Board circuitry:

(DS1-1, -2, -3, -4, -5): Simulate each of the {4) Pumps Running; (They must be "OFF" in Normal Operating Mode).

PAGE 8 OF 24


b. (DS1-6): Comparator Amplifier Offset; (It must be "OFF", unless otherwise required by the Board).

c. (DS1-7): Simulates Output Current Feedback Signal; (It must be "OFF" in Normal Operating Mode).

11. (DS2), DIP Switch, 6- Positions, needed to setup the Board functions:

a. (DS2-1 ): Unit restart after a "GENERATOR LEAK" Condition: ;.. "ON": Unit restarts automatically ;.. "OFF": Unit does not restart automatically ;.. (It must be "OFF" in Normal Operation; ;.. Unit must be reset by turning the Main Disconnect Switch (DS1) "OFF", then "ON"

b. (DS2-2): Unit can be reset using the "RESET PUSHBUTTON" (PB1) ;.. ON": Unit can be reset; ;.. "OFF": Unit can not be reset. ;.. (It must be "OFF" in Normal Operation)

c. (DS2-3): Generator Leak simulation for Board setting: ;.. "ON": Leak is detected; ;.. "OFF": Leak is not detected. ;.. (It must be "OFF" in Normal Operation).

d. (DS2-4): Unit restart after a "LOW FLOW" Condition: ;.. "ON": Unit restarts automatically; ;.. "OFF": Unit does not restart automatically. o (It must be "ON" in Normal Operation)

e. (DS2-5): Unit can be reset using the "RESET PUSHBUTTON" (PB1 ): ;.. "ON": Unit can be reset; ;.. "OFF": Unit can not be reset. o (It must be "OFF" in Normal Operation)

f. (DS2-6): Normal Flow simulation for Board setting: ;.. "ON": Flow is Normal; ;.. "OFF": Flow is Low. o (It must be "OFF" in Normal Operation)

C. Located on the PC3/PC4 (IGBTBoards):

1. (CR3), LED, Green, indicating the presence of(+) 15 V DC on the 1/2 Board;

2. (CR4), LED, Green, indicating the presence of(-) 15 V DC on the 1/2 Board;

3. (CR11 ), LED, Green, indicating the presence of(+) 15 V DC on the 1/2 Board;

4. (CR12), LED, Green, indicating the presence of(-) 15 V DC on the 1/2 Board;

PAGE 9 OF 24

"'


4.3.2.10 Grounding

The Enclosure Assembly is made of several Structures, in a modular construction, sealed by Gaskets, and fastened by Hardware.

To provide proper Enclosure grounding, the Enclosure must be grounded by:

1. Running a minimum of #6 AWG (16mm 2) GROUNDING CONDUCTOR between the External Enclosure Grounding Stud and the surrounding Grounding Grid.

PLUS

2. The EQUIPMENT GROUNDING CONDUCTOR part of the 460 V AC Feeder, connected to the Main Disconnect Switch (DS1 ), Terminal GND.

The unit is provided internally with a MAIN GROUNDING Stud, welded to the Enclosure. All internal components required to be grounded are radically grounded to this Stud.

The hinged door is provided with a welded grounding Stud, connected to the Enclosure Main Grounding Stud.

The NEGATIVE Side of the power supply is grounded to the Main Grounding Stud.

The 460 V AC Feeder's Equipment Grounding conductor (supplied with the Feeder) is wired to the Terminal GND on the Main Disconnect Switch (DS1 ), which in turn is wired to the Internal Main Grounding Stud.

4.3.3 FIELD ADJUSTMENTS

Some Switching Power Supply Field adjustments are required on the PC1) Pulse Width Modulation Board) and the PC2 (CHLOROPAC® Control Board).

All the adjustments able to be done in the Shop, were done in accordance with the Engineering Specification SP-82389, and the Power Supply was tested accordingly.

The MINIMAL Field adjustments are required to setup the unit for the real/Field working conditions.

All the adjusting Operators/Devices/Indicating Lights and their function are described in detail Paragraph 4, 3, 2, 8.

4.3.3.1 Field Adjustments for the CP1 (Pulse Width Modulation) Board:

The DC CURRENT LIMIT and the DC OVERVOLTAGE LIMIT must be performed at sea as specified in Paragraphs 4.3. 7 and 4.3.8.

PAGE 10 OF 24


Field Adjustments for the CP 2 (Chloropac® Control) Board: 4.3.3.2

The CHLOROPAC® Control Board contains all the features for the AUTOMATIC Operation. The Board was Factorv adjusted in accordance with the Engineering Specification SP-82389.

The Board offers two REMOTE CONTROL options:

A. Analog Signal:

0-to-20 mA (or 4-to-20 mA) and 0-to-10 V DC (or 2-to-10 V DC) from a remote Linear Source. The Input Signal Load Resistor "R18" is 500 Ohms, 1%.

The DC OUTPUT CURRENT is LINEAR, and it is proportional to the INPUT Signal Value.

(e.g. Considering a 0-to-1 0 V DC will produce the Rated DC Output, then 25% of 1 0 V DC= 2.5 V DC will produce 25% of Rated DC Output).

The Board OFFSET Trimmer (R34) was set for 0.000 V DC.

If a Signal different than 0-to-... (e.g. 2-to-1 0 V DC or 4-to-20 mA) is being used, then the following Field adjustments are required.

1. Reduce the Input Signal to the minimum Value, say 2.000 V DC:

);> Negative Lead to Board Test Point "TPO" (near LED1 );

);> Positive Lead to Board Test Point" TPA" (near R34 Trimmer);

2. Connect a Digital/ High Impedance Voltmeter:

3. Set Voltmeter to the Lowest Scale of DC Volts;

4. Rotate Trimmer "R34" clockwise until Meter reads(-) 2.000 V DC;

5. Remove the Digital Voltmeter. The OFFSET adjustment is complete.

As such, a CONTINUOUSLY VARIABLE I ANALOG Control Signal can generate a CONTINUOUSLY VARIABLE DC Current Output.

B. Digital Signal:

(Running Pump Signal)

The Board contains four 120 V AC Relays, 50/60 Hz., @5 Watt, Rated per IEC 255, with Single-Pole-Double-Throw, Dry (From "C© Contact. The Relay Coils are isolated from each other, and from the Board circuitry. All the Relay Coil terminals are wired to the Terminal Block TB1 02, Terminals 14 through 21.

PAGE110F24

...

•

....


The Relays must be energized with 120 V AC, Single Phase, from an OUTSIDEOF-POWER-SUPPLY Source, each by an associated running Pump, through a Pump permissive "ON-OFF" dry I voltage free contact.

When energized, each Relay Contact on the Board will close a Board Circuit, producing an adjustable 0-to-10 V DC Signal, and generating a Power Supply DC Output.

The CHLOROPAc® Control Board was Factory adjusted considering four Pumps, each with the same flow, equal with 25% of the TOTAL REQUIRED SEA WATER FLOW.

As setup, each running Pump generates 2.500 V DC simulated Signal, and will produce 25% of the Power Supply DC Rated Current Output.

The Board must be reset in the Field for the FIELD conditions as described below:

(The following is just an example; the real Field conditions shall be applied).

--* Pump No. 1: MAIN Pump, with a flow of 75m 3/h;

--* Pump No.2: AUXILIARY Pump, with a flow of 15m31h;

--* Pump No.3: FIRE Pump, with a flow of 1 Om 31h;

--* Pump No.4: No Dosing Required, flow not important.

The TOTAL DOSED = 100 m3/h Flow

Let us also assume:

--* To dose I Chlorinate the TOTAL Flow we need an DC CURRENT Output of 450 A DC:

--* The Unit is Rated 450 A DC, at 14 V DC:

--* The Board is set to Output 450 A DC for an Input Signal of 10.00 V DC.

Each RUNNING Pump must generate a proportion of the 10.00 V DC Signal equal to the Ratio of the Pump's Flow to the TOTAL Flow:

PAGE 12 OF 24


1. To Chlorinate the Flow circulated by the Pump No. 1:

2.

3.

a. 75 m3/h /100 m3/h = 75%

b. 75% x 10.00 V DC= 7.50 V DC:

c. 75% x 450 A DC= 337.5 A DC will chlorinate 75 m3/h

To set up the Board for the 75% Input Signal for Pump No. 1 does the following:

(This Field Adjustment should be done immediately after the Pump Supply installation, with no DOSED Pumps running)

d. Connect a Digital/ High Impedance Voltmeter;

Y Negative Lead to Test Point TPO (near LED1 );

Y Positive Lead to Test Point TPC (near R34 Trimmer);

e. Switch the (Ds1-1) to "ON" position;

f. Rotate Trimmer (R1) (associated with Pump No. 1) until Meter reads 7.500 VDC;

g. Switch the (DS1-1) to "OFF" position.

The DOSING for the Pump No. 1 is now completed.

To Chlorinate the Flow circulated by the Pump No.2:

a. 15m3/h. /100 m3/h. = 15%

b. 15% x 10.00 V DC= 1.50 V DC;

c. 15% x 450 A DC= 67.5 A DC will chlorinate 15m3/h

d. Switch the (DS 1-2) to "ON" position;

e. Rotate Trimmer (R2) (associated with Pump No. 2) until Meter reads 1.500 VDC;

f. Switch the (DS1-2) to "OFF" position.

The Dosing for the Pump No. 2 is now completed.

To Chlorinate the Flow circulated by the Pump NO.3:

a. 10m3/h./10m3/h.= 10%

PAGE 13 OF 24

II>'

1111

.. !!>,,,


b. 1 0% x 1 0.00 V DC= 1.00 V DC;

c. 1 0% x 450 A DC= 45.0 A DC will chlorinate 1 0 m3/h.

d. Switch the (DS1-3) to "ON" position:

e. Rotate Trimmer (R3) A(associated with Pump No. 3) until Meter reads 1.000 VDC;

f. Switch the (DS1-3) to "OFF" position.

The DOSING for the Pump No. 3 is now completed.

4. To Chlorinate the flow circulated by the Pump No.4:

a. We assumed, Pump No. 4 Flow is not required to be Chlorinated;

b. Leave (DS1-4) to "OFF" position;

c. Do not adjust Trimmer (R4) (associated with Pump No.4).

Pump No.4 does not require adjustment.

5. The TOTAL Signal= 7.50 VDC + 1.50 VDC + 1.00 VDC + 0.0 VDC = 10.00 VDC. For a Unit Rated 450 A DC Output, 10.00 V DC will produce 450 A DC Output.

6. The TOTAL Current= 337.5 ADC + 67.5 ADC + 45.0 ADC +0 ADC = 450 ADC

7. If a Power Supply is Rated, say, 450 A DC, but the DC Current required to chlorinate a TOTAL Flow of 100 m3/h is different than the Maximum I Rated Current, say, 315 A DC, the following prorating must be implemented:

a. 315 A DC required /450 A DC Rating= 70%

b. 70% x 10.00 V DC= 7.00 V DC:

c. Pump No. 1 requires: 75% x 7.00 V DC= 5.25 V DC;

5.25 V DC x (450 A DC /10.00 V DC) = 236.25 A DC

d. Pump No.2 requires: 15% x 7.00 V DC= 1.05 V DC;

1.05 V DC x (450 A DC /10.00 V DC)= 47.25 A DC.

e. Pump No.3 requires: 10% x 7.00 V DC= 0.70 V DC;

0.70 V DC x (450 A DC /10.00 V DC)= 31.50 A DC

PAGE 14 OF 24


Pump No.4 requires: 0% x 7.00 V DC= 0.00 V DC f.

0.00 V DC x (450 A DC /10.00 V DC) = 0.00 A DC.

g. TOTAL Current= 236.25 A DC+ 47.25 A DC +31.50 A DC+ OA DC= =315.00ADC

Following the above examples, the Pump Signals SETIING could be achieved for any other combination of running Pumps and Volts /Amps Output Rating.

4.3.4 INITIAL OPERATION

Initial energizing is as follows:

NOTE: The following energizing to be performed in open sea water.

1. Establish sea water flow to Generator at 25 GPM (minimum):

2. Energize the 460 or 380 VAC Feeder to the Switching Power Supply;

CAUTION

If the power source for the Switching Power Supply is 380 V AC, the tap on Transformer (T3) must be changed from the 460 V AC position to the 380 V AC position. Failure to do so will cause the equipment to malfunction and could cause damage to the control circuits.

3. Turn AC Input Main Disconnect Switch (DS1) "ON".

The "POWER ON" light (LT1) must be "ON". If it is not "ON", turn "OFF" the Main Disconnect Switch (DS1), and check the Control Transformer Fuse (F4) for interruption.

Repair I replace and repeat the previous steps;

4. Under normal operating conditions, the "NORMAL FLOW" Green light (LT4) must be "ON". If "LOW FLOW" Red light (LT5) is "ON", inadequate flow of sea water passes through the Generator.

Correct the FLOW PROBLEM and continue;

5. Turn the AUTO I MANUAL Selector Switch (SW1) to "AUTOMATIC" mode;

6. Field Automatic set: The unit is Factory set; Minor Field adjustments might be required. See paragraph 4.3.3.

7. Rotate the Current Limit Potentiometer (R1) fully clockwise to allow for the RATED DC Output Voltage;

PAGE 15 OF 24


8. Under normal operating conditions the "GENERATOR LEAK" Red light (L T3) must be "OFF". If the Red light is "ON", there is a Generator Leak condition.

Correct the GENERATOR LEAD PROBLEM and continue.

9. Adjust Current Limit Potentiometer (R1) clockwise until current is 450 Amperes DC at 28 V DC. Lock the Operator at this setting.

10. Make sure the Seawater Flow Light (LT4) indicates a "NORMAL FLOW" condition. Temporarily set Auto/Manual Selector Switch (SW1) to "MANUAL" mode. This bypasses the Leak safety feature, and permits operation/testing throughout the range of the equipment for temporary periods.

11. Rotate the MANUAL Adjust Potentiometer (R2) clockwise, and observe the increase of the DC OUTPUT Current and Voltage;

12. Rotate (R2) counterclockwise to reduce the DC OUTPUT to 0 Amps and 0 Volts.

Leave Operator (R2) in the fully counterclockwise position to prevent the full DC Output in the case that the Selector Switch (SW1) is switched from "AUTOMATIC" to "MANUAL" position.

13. Set Auto/Manual Selector Switch (SW1) to "AUTOMATIC" Mode for normal operation.

4.3.5 NORMAL OPERATION (AUTOMATIC)

Once the HIGH OUTPUT CURRENT and HIGH OUTPUT VOLTAGE LIMITS were set, no further adjustments are required on the Power Supply. The Power Supply will AUTOMATICALLY adjust its DC output voltage due to changes in water temperature and minor changes in salinity in order to maintain the required DC current Output.

The flow of sea water should be maintained through the Generator at all times even if the power is secured. If the Generator is to be secured for long periods of time, it should be drained by opening both the Generator Drain Valve (Located on the Outlet Cell Nut) and the Generator Vent Valve (Located on the Inlet Cell Nut) if it is so provided, or breaking the Inlet flange to allow the air venting.

For NORMAL OPERATION, the Green light (LT4) must be "ON", and no Red light be "ON". When any of the Red lights (LT2, LT3 or LTS) are "ON", the DC OUTPUT from the Power Supply is SHUT OFF.

PAGE 16 OF 24


These safety features should never be bypassed because of the protection it affords to the equipment.

4.3.6 MANUAL OPERATION

The Power Supply may be operated in the "MANUAL" Mode temporarily until repair can be made to the "AUTOMATIC" controlling circuitry.

It is NOT RECOMMENDED that the system be operated for prolonged periods in the "MANUAL" Mode because of the potential danger that can be done to the Generator in case of an internal Leak.

In "MANUAL" Mode, the AUTOMATIC SHUT DOWN feature Of the system for Leak control is bypassed.

The Overcurrent Cut-out is still operable in the "MANUAL" Mode.

4.3.7 CURRENT LIMITING

CAUTION

This adjustment must be made when the ship is in salt water. It is not possible to set the current limit in fresh or brackish water because the water is not sufficiently conductive.

A CURRENT LIMIT feature has been incorporated in the Power Supply (1 0-Turn Trimmer (R2) on the PWM Control Board, and Potentiometer (R1) on the unit door) which limits the DC Output Current regardless of whether the Selector Switch (SW1) is placed in "AUTOMATIC" or "MANUAL" Operating Mode.

Turning the CURRENT LIMIT ADJUST Potentiometer (R1) clockwise increases the HIGH LIMIT of the DC Current Output and turning counterclockwise decreases the HIGH LIMIT of the DC Current Output.

On-Board mounted Trimmer (R2) extends the controlled range. This is a Factory Set device, and it shall not be readjusted unless so instructed by Siemens Water Technologies.

The PWM Board is also provided with a Current Limiting visual indication. A Yellow color (LED3), when lit, indicates the Power Supply is in the Current Limiting Mode.

After setting the correct High Current CUT-OUT, lock the operator by rotating clockwise the locking mechanism.

PAGE170F24


4.3.8 OVERVOLTAGE CONTROL

CAUTION

This adjustment must be made when the ship is in salt water. It is not possible to set the current limit in fresh or brackish water because the water is not sufficiently conductive.

An OVERVOLTAGE LIMIT feature has been incorporated in the Power Supply (1 0-Turn Trimmer (R1) on the PWM Control Board) which limits the DC Output Voltage regardless of whether the Selector Switch (SW1) is placed in "AUTOMATIC" or "MANUAL" Operating Mode.

Turning the voltage LIMIT ADJUST Trimmer (R1) clockwise increases the HIGH LIMIT of the DC Voltage Output and turning counterclockwise decreases the HIGH LIMIT of the DC Voltage Output.

On-Board mounted Trimmer (R1) is a Factory Set device, and it shall not be readjusted unless so instructed by Siemens Water Technologies.

The PWM Board is also provided with an Overvoltage visual indication. A Yellow color (LED4), when lit, indicates the Power Supply is in the Overvoltage Limiting mode.


4.4.1 POWER SUPPLY ENCLOSURE

Since the Switching Power Supply has no major moving parts to be lubricated or adjusted, the only maintenance recommended is the daily operating readings. If the readings indicate the Power Supply is not performing properly, refer to Service Section 4.4.2.

Cabinet Fans

Inspect the fan blades on the cooling fans. Remove any accumulation of dust on the blades and fan motor.

Cabinet

Inspect the cabinet internals. If there is dust, clean using a small vacuum cleaner and soft brush.

Heat Sinks

Inspect the Heat Sinks located on the back of the cabinet. If dirty, clean by running a soft brush over the Heat Sink fins.

PAGE 18 OF 24


4.4.2 CHLOROPAc®CONTROL BOARD RESETIING

If Power Supply does not perform any longer within the limits of the initial adjustments, the CHLOROPAc® Control Board must be readjusted as described in Paragraph 4.3.3.

4.4.3 TROUBLESHOOTING AND REPAIR

4.4.3.1 Procedures

It is not the intention of this section to provide ~ troubleshooting procedures to effect detailed repairs to the Chlorination system.

The purpose of this section is:

> to locate a faulty subassembly or system component in the overall system'

> to get the system back on line as quickly as possible;

> to order proper parts; and/or

> to inform a Siemens Water Technologies repair technician of problems with the system.

Generally, there are no repairs possible to a subassembly or a component, and the item will be replaced. Details on replacement of components is not provided, as the normal replacement procedures consist of removing and reconnecting fasteners, disconnecting and reconnecting wires, and unsoldering the soldering wires.

Data recorded on the Chlorination System log sheets will be helpful in determining problems with the system. This data should be reviewed before starting the troubleshooting tests. More than one fault may be present at the same time so there may be a number of symptoms. After corrective maintenance is performed, the system should be checked to see if proper voltage and current levels for the given water conditions are being delivered.

See Section 4.4.3.2. This will uncover any fault which may have been masked by other faults.

4.4.3.2 Troubleshooting Charts

WARNING

Hazardous voltages are present in this equipment. Ensure all tag out procedures are in accordance with current shipboard instructions. Failure to comply with tag out procedures could result in injury to personnel, and damage to equipment.

PAGE 19 OF 24

..

•

-,..,

•

...

...


The Troubleshooting Charts listed in TABLE 4-1 are used to localize most of the troubles within the system. Terminals listed in this Table are located on the piece of equipment they reference.

The following is a list of these Tables:

TABLE 4-1. Troubleshooting Chart- Power Supply

TABLE 4-2. Fuse Chart

CAUTION

The following Troubleshooting Charts allow troubleshooting only to the capability level of most shipboard operators and electricians.

Troubleshooting and repair beyond the symptoms and repairs listed below should only be performed by or under the direction of a Siemens Water Technologies Product & Services repair technician. Schematic diagrams in this manual only support troubleshooting to this level. The CCB controller, PWMB control and IGBT drivers are solid state devices and require sophisticated instruments to troubleshoot.

Serious damage to eauipment can occur if repairs beyond those covered below are attempted, without detailed knowledge of the system components.

4.4.3.3 Voltage Checks

The following voltage checks can be made if troubleshooting procedures do not pinpoint the malfunction. This procedure should also be followed after repairing a Power Supply. Sequential inspection will help prevent mistakes in repair.

A. The following voltage measurements are made with the Power Supply circuit disconnected:

1. Turn "OFF" the 3-Phase power Circuit Breaker at the Client's Panel, and secure Main Disconnect Switch (DS1) in the "OFF" position.

2. Place (SW1) in "MANUAL";

3. Adjust (R2) fully clockwise;

4. Break the secondary of (T3) by disconnecting the control wire connected to (T3) terminal (X1) (HOT/LINE Leg);

5. Temporarily apply 120 V AC, Single Phase, from an external Source, to supply 120 V AC to Power Supply control circuitry, without using Transformer (T3):

PAGE 20 OF 24


a. Connect 120 V AC HOT/LINE wire to the control wire disconnected from (51);

b. Connect 120 V AC NEUTRAL wire to Transformer (T3), terminal (X2).

Normal voltages should read as follows;

Terminals Voltage Check:

Secondary of (T3) (X2 120 V AC At Transformer for control and Fan power, (NOTE: and HOT/LINE wire) (T3) secondary is bypassed).

PWM Board @+15 V DC LED Illuminated

PWM Board @-15VDC LED Illuminated

CC Board @+15 V DC LED Illuminated

CC Board @-15 V DC LED Illuminated

DRIVER Board @+15 V DC LED Illuminated

DRIVER Board @-12 V DC LED Illuminated

DRIVER Board +15V to 14kHz Gate Signal. Output Signal from G to E, -12V Square wave 150 ns max. found twice on each

card

B. Make these measurements last, with 460 V AC connected to the power circuit.

To reconnect the Power Supply circuit,

1. Disconnect the temporary 120 V AC Source from Transformer (T3);

2. Reconnect control wire to transformer (T3), terminal (X1 );

3. Place (SW1) in "MANUAL" mode;

4. Adjust (R2) fully counter-clockwise;

5. Turn "ON" Clients Circuit Breaker, and Power Supply Main Disconnect (DS1);

Normal voltages should read as follows:

PAGE 21 OF 24

""

...

SIEMENS Terminals

DS1-1 and 2 DS1-2 and 3 DS1-3 and 1 C1 to E2

Voltage

460+/- 46 V AC 460 +1- 46 V AC 460 +1- 46 V AC 650 ± 65 DC

Water Technologies

Check:

3 phase input, line after the Main Disconnect Switch (DS1)

Across Transistors Q1/Q2 power terminals.

6. Turn the Power Supply "MANUAL OUTPUT" adjustment (R2) up to about 25% of Rated Output. Continue taking measurements.


DC 1/4 of Rated Output, Output voltage. P1 and N1

Measurement taken across Power Supply Output:

(+) 3.5 V DC for 14.0 V DC Rating; (+) 7.0 V DC for 28.0 V DC Rating.

7. Turn the Power Supply "MANUAL OUTPUT" adjustment (R2) up to 100% of Rated Output. Continue taking measurements.


DC Output, P1 and N1

1 00% of Rated Output voltage.

Measurement taken across Power Supply Output:

(+) 14.0 V DC for 14.0 V DC Rating; (+) 28.0 V DC for 28.0 V DC Rating.

PAGE 22 OF 24


TABLE 4-1 Troubleshooting Chart- Switching Power Supply

Malfunction: Probable Cause Corrective Action: Power to unit is secured at Client's Turn power ON at Client's Breaker Panel. Breaker Panel.

POWER ON Lamp LT 1 does Bulb faulty Replace Bulb

Replace F4 Fuse not illuminate when Main Disconnect Switch DS 1 is

Fuse F4 Blown

turned ON. See TABLE 4-5

DS1 Faulty Replace Disconnect DS1. See TABLE 4-5

Transformer T3 Replace T3.

Faulty Voltmeter indicated normal

Ship is in fresh or Voltage, but the Ammeter None required. indicates reduced Current.

brackish water.

Disconnect 460 (38) VAC from Power Supply

Shorted Rectifier input. Measure Forward and Reverse

in Diode Bridge. resistance one at a time across each phase. Shorted Rectifier will measure 0 ohms one way and> 1M the other.

Bad Surge Disconnect Surge Suppressor and measure with digital volt/ ohm Meter. Resistance

Suppressor SA 1 -should be less than 10 ohms. If bad, replace

Main AC Input Fuse F1, 2, 3 SA3. Suppressor.

Open. Disconnect 460 (380) VAC from Power Supply

Shorted EMI Filter input. Measure resistance. If Meter reads 0 ohms, replace Filter. Disconnect 460 (380) VAC from Power Supply input, Measure Forward and Reverse

Shorted Transistor. resistance one at a time across each phase. A shorted transistor will measure 0 ohms each way. If bad, replace Transistor.

Current Limit R2 Readjust the Current Limit setting so that total

improperly set. Fuse Ratings are not exceeded. If bad, replace Fuses.

Output Fuses F5-F6 blown. Shorted Generator Clear Cells Short: Cells (Internally or Externally) If bad, replace Fuses.

Open Main AC Measure current to Power Supply with

Fuse on one Line induction Ammeter. Open Line will read zero

Unbalanced AC line Current Current.

and/or less than Rated. Measure current to Diode Bridge with

Open Bridge induction Ammeter. Open diode will read 1/2 Rectifier D3. Current of other Phase. If bad, replace

Rectifier.

PAGE 23 OF 24

• •


TABLE 4-2 Fuse Replacement Chart

Service Fuse Part No.: Fuse Size: Fuse Type; AC Power: AC Input Fuses F1, F2, F3 for: 1/2 lb/h, 1 lb/h & 2 lbs /h A3-74666-01 0 (3 Pes) 20 AMP, 500 V AC Time Delay/ Show Blow Units 4 lbs/h Unit AC-74666-012 (3Pcs) 30 AMP, 500 V AC

Transformer T3: Primary Fuse F4 A3-74666-013 (1 Pc.) 2 AMP, 500 V AC Time Delay I Slow Blow

DC Power: Output Fuses F1 and F2 For: 130 ADC Units A3-55658-003 (1 Pc.) 150 AMP, 130 VDC Extremely Fast, 225 ADC Units A3-55658-013 (2 Pes.) 125 AMP, 130 VDC For Semiconductors 450 ADC Units A3-55658-008 (2 Pes.) 250 AMP, 130 VDC Protection.

4.5 POWER SUPPLY DRAWINGS

PAGE 24 OF 24

' I

lr 32" [813]

20" [508] •m

~

•

L ______ _

AIR FLOW

~

9/16• (14] DIA. HOt.! THRU (4) RECIO

STATUS LAMPS

~ AWP & VOLTAGE

I LOWI.4=~1.1Al . FLOW INDICA 1100

LEAK DETECTION STATUS L.AWPS

AUTO MANUAL SELECTOR S'MTCH MANUAL & CURRENT Ut.tiT AOJJST POTENllOWETERS LEAK DETECTOR RESET

SECURITY DOOR FASTENER TYP.

1. ALLOW 24 INCHES FRfi SPACE ABOVE 00 BELOW, ENCLOSURE FOR CONVECTlON COOUNG OF' ~NED HEAT SINKS.

2. All ELECTRICAL CABLES ENTER niROUGH BOTTOU Of POWER SUPPLY.

3. UNSIZED CONDUCTORS TO BE MINit.IUI.I 16AWG (1.5mm2)

4. REUOVE .ut.4PER FROU PINS 2 TO 3 ON 18102 ~EN USING AN EX"TERNAL 4-20mA CONTRa... SIGNAL JJUPER INSTAU.ED F'OR PVNP SWITCHING OPERATlON.

5. FOR SPARE PARTS UST REFER TO WAINTENANCE AND OPERATlONS WANUAL

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1/4-20 X 3/4" [19}-j GROUND SlUD

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CABLE TERMINATION DIAGRAM N.T.S.

l' ' ' ' 11 ' '

QESIGN ANQ PERFQRMANCE DATA

INPUT VOLTAGE: 460VAC ±10X/3*/60Hz ±5%

INPUT kVA: 13.8 MAX

OUTPUT POWER: 450A.DC, 28WC, 126kW (MAX AT 50"C AMBIENT m.tP.)

CONSTRUCTION: WALL OR BULKHEAD UOUNTED ENCLOSURE CONSTRUCTION TO IP-23.

AL.ARU CONTACT RATING: 0.6A. 125VAC

FUSE DATA: INPUT: F1, F2, F3, 30A, P/N 74666-012 CONTROl: F4, 2A, P/N 74686-013 OUTPUT' (2) DC FUSES PER GENERATOR CHJ., F5, F6, 250ADC, P/N 55658-250

'

APPUCATION: 50682-004SW-02 POYIER SUPPLY FOR ... lb/h WITH 26 VOLTS ON GENERATOR TERUINALS, VOLTAGE DROP NOT EXCEED 2 VOLTS.

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FRa.f BOITO&ol Of FRONT DOOR APPROxn.IAlE WEJGHT: 235tl (107kg)

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INLET

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82428-4

OUTLET

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82426-14

NOTES:

1. THE AIR BLO-.:RS B3, 84, BS. THE THERMAL SENSOR KS, AND ASSOCIATED WIRING SHALL BE ONLY INSTALlED ON THE lei ASSBABUES THAT OUTPUT 450ADC (BOTH 15WC AND 30\IOC).

2. WITH THE JJMPER CONNECTED AT 18102, TERMINALS 2 AND 3, THE DC OUTPUT IS CONlROLLED PROPOR110NAL TO THE FlOW Of THE PUMPS. WITH REMOTE INPUT SIGNAL (0-20mA OR 0-10VDC), DISCONNECT ..JUMPER TO CONTROL THE DC OUTPUT.

3. ID DENOTES A SHEET INTERFACE FOR WIRES OR CABLES THAT CONNECT TO OTHER SHEETS PER THE LEGEND BELOW:

__.WillfiL --- OENOlES HARNESS ASSEMBLIES

--- DENOTES INOI\'10UAL '111RES

~INTERFACE DESIGNATOR (EX: CONNECT TO 014)

~SHEET AND ZONE (EX: 207 MEANS SHT 2 ROW 0 COLUMN 7)

111\.[ WIRING DIAGRAM 1,..;:._ t.=-1 SVItTCHING POWER SUPPLY

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1.) FOR PROPER VOLTAGE CONTROl, SET THE PROPER VOLTAGE SELECTOR DS1 ON THE PY!\1 CARD.

II I II II A I ISSUED F"OR CONS"IRUC"TION S' ISY

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SECTION V

INLET I OUTLET ASSEMBLIES

5.1 GENERAL

The Inlet and Outlet of each shipboard Generator are manufactured of 7/16" thick, 1-1/2" Titanium flange with 5/8" bolt holes, and they meet MSS standards.

5.2 DETAILED DESCRIPTION

5.2.1 INLET FLOW METER ASSEMBLY

The Flow Meter is provided to give a visual indication of the water flow within the Generator in either GPM (Gallons per Minute) or LPM (Liters per Minute).

Depending on the piping size and the Flow velocity, the 8035 Burkert Flow Meter can measure and display flows from 0.3 GPM up to 300 GPM.

For this Generator application, the Meter Piping is 1-1/2 inch NPS, and it has a measuring range of 1-1/2 GPM at 0.3 Ft/s up to 180 GPM at 30 Ft/s.

However, due to the Generator's requirements, the Maximum Flow rate used for Generator cleaning, or otherwise, must not exceed 40 GPM.

See FIGURE 5-1 at the end of this Section, and TABLE VII- 4 for Spare Parts.

5.2.1.1 FLOW TRANSMITTER

The Flow Transmitter is provided with every Generator and Power Supply to allow for continuous flow measurement of the water through the Generator and to shut down the CHLOROPAc® system in the event of Low water flow.

5.2.1.2 DESIGN

The compact Flow Transmitter combines a Flow Sensor and an Electronic Board with a Display.

The Sensor consists of a Transducer mounted in a 1-1/2 inch pipe;

The Transmitter components convert the measured signal and display the actual value;

The Output Signal is carried via a 5-pole cable plug or via a cable gland.

PAGE10F14


The following parts of the Transmitter come in contact with the sea water (wetted parts):

Transmitter Part Material

Paddle-Wheel PVDF

Axis and Bearing Ceramic

Sensor Housing PVDF

5.2.1.3 PRINCIPLE OF OPERATION

When liquid flows through the pipe, the Paddle Wheel is set in rotation inducing a measured frequency in the Transducer, which is proportional to the flow.

The Flow Transmitter is wired for either 230 or 115 V AC, 50/60 Hz, from the Power Supply.

5.2.1.4 INSTALLATION

The Flow Transmitter 8035 can be easily installed into the piping system and the wiring connections are via the cable plug.

5.2.1.4.1 SENSOR HOUSING and TRANSMITIER INSTALLATION

(Refer to FIGURE 5-1 at the end of this Section)

Flow Sensor and Transmitter is factory assembled as a 34- 3/4 inch long spool piece with 1 - 1/2 inch ANSI flanges on both ends.

The new Meter is installed in line with existing or new customer piping.

5.2.1.4.2 ELECTRICAL WIRING

To open the connector, remove screws 1 and 2. Remove internal part 3 from external part 4. Connect according to pin assignment. When re-assembling, the internal part may be inserted into the external part in 90° step intervals as required.

5.2.1.4.3 LOW FLOW LIMIT SWITCH RELAY CONTACT SETIING

The Relay contacts are calibrated at the factory.

PAGE 2 OF 14

..

"'"

...


The following procedure (and Calibration points) is used to re-calibrate the Flow Transmitter should there be a need to, such as in a new Transmitter (See Section 5.2.1.5. 9 for general re-calibration of Relay action):

1. Press" Down Arrow" and "Enter" Keys simultaneously for (5) seconds:

2. Continue to press "Down Arrow" key until "RELAY" is displayed and then press "Enter" Key;

3. Enter "24.5" ("1-24.5" is displayed) and press "Enter" (This sets up the Hysteresis);

4. Enter "25.0" ("1 +=25.0" is displayed) and press "Enter";

5. Press "Down Arrow" for "NO" ("INV NO" is displayed) and press "Enter;

6. Enter "24.5" ("2-=24.5" is displayed) and press "Enter";

7. Enter "25.0" ("2+=25.0"" is displayed) and press "Enter";

8. Press "Down Arrow" for "YES" ("I NV YES" is displayed) and press "Enter".

The Relay contacts are now calibrated for "Low" and "High" flow.

5.2.1.4.4 CONTACT WIRING

The wiring for the Sensor connections for high and low contacts is as follows (See Installation Drawing, FIGURE 5-1, at the end of this Section):

Sensor Contact Numbers Relay Output

7 and 8 Low Sensor

9 and 10 High Sensor

5.2.1.5 TRANSMITTER OPERATION and CONTROL ELEMENTS

The following procedures are used when installing a new unit, changes to the system or Calibration.

5.2.1.5.1 KEYPAD DESCRIPTION

The functions of the three keys on the Keypad are as follows:

1. The "Up Arrow" key is used for choice of digit valve (90 to 9);

PAGE 3 OF 14


2. The "Down Arrow" key is used for direction downwards in menu or sideways for digit selection;

3. The "Enter" key is used to accept the chosen parameter or adjusted value;

4. Relay 1 contact is Normally Open and Relay 2 contact is Normally Closed.

5.2.1.5.2 OPERATION MODE DISPLAY

The following four variables are displayed in the Operation mode. Pressing the "Down Arrow" key will display each of these variables:

1. xxxGPM Flow rate in the required engineering unit (see Calibration menu);

2. xxxmA 4 to 20 mA output signal, proportional to the flow according to the selected measuring range;

3. xxxGPM Main Totalizer in the required engineering unit (see Calibration menu to reset Totalizer); Reset in the Calibration menu;

4. xxxGPM Daily Totalizer in the same engineering units as the main Totalizer. A point behind the unit differentiates it from the main Totalizer. Reset by simultaneously pressing the "Up Arrow" and "Down Arrow" keys for (2) seconds.

5.2.1.5.3 CALIBRATION MODE DISPLAY

This is the main menu, which consist of ten sub-menus and are listed below.

To enter this display press the "Down Arrow" Key and "Enter" Key Simultaneously for (5) seconds. Pressing the "Down Arrow" key displays each of the submenus:

1. LANGUAGE This selects between English, German, French and Italian;

2. UNIT

3. "K-FACTOR"

4. CURRENT

5. PULSE

6. RELAY

Selects engineering units to display flow rate and Totalizer

(LPM =Liters per minute or GPM =Gallons per minute);

Input of "K-Factor" (according to TABLE 5-1 in this Section), or use of "Teach-in" function in order to determine the specific "K-Factor":

Determination of the 4 to 20 mA measuring range;

Parameter definition of Pulse Output (unit and quantity);

Parameter definition of Relays. This message only appears if the Relay option has been installed;

PAGE 4 OF 14

...

•

...

...

....

""

"'


7. FILTER Dampening selection. There are 10 different steps available;

8. TOTAL Totalizing resetting;

9. CODE For internal Burkert use only;

1 0. END Return to operation mode and storage of new parameters.

5.2.1.5.4 LANGUAGE

This function allows for the operator to choose a language for the Display.

From the calibration mode display press the "Down Arrow" key until the "LANGUAGE" function is displayed, and press "Enter".

With the "Down Arrow" key the Meter displays in one of the four languages:

1. ENGLISH (Select this Language for the English speaking Operators)

2. DEUTSCH (Select this Language for the Deutsch speaking Operators)

3. FRANCAIS (Select this Language for the French speaking Operators)

4. ITALIANO (Select this Language for the Italian speaking Operators)

Press the "Down Arrow" key for the required language, which is confirmed and activated via the "Enter" Key.

This also brings the operator back to the Calibration mode.

5.2.1.5.5 ENGINEERING UNITS

This function allows the operator to choose an engineering unit from the Calibration mode.

Press the "Down Arrow" key until the "UNIT" function is displayed and press "Enter". Press the "Down Arrow" key for the desired Engineering Units:

1. LITIERS /SECOND,

2. /MINUTE,

3. /HOUR.

4. CUBIC METERS /MINUTE,

5. /HOUR.

PAGE 5 OF 14


6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

US GALLONS

IMPERIAL GALLONS

/SECOND,

/MINUTE, (SELECT THIS OPTION)

/HOUR.

/SECOND,

/MINUTE,

/HOUR.

After the Unit has been picked, press the "Enter Key and the flow can be displayed in any engineering unit with 0, 1, 2, or 3 decimal places.

Following are Decimal displays after pressing "Down Arrow":

DEC PT 0 (decimal point 0)

DEC PT 1 (decimal point 1) (Select this Option)



Pick the number of decimal places and press "Enter", which sets the value and brings the operator to the TOTAL sub-menu. This menu allows the operator to pick a name for the Engineering Units.

Displays are as follows:

L (for liters)

M3 (for cubic meters)

US GAL (for US gallons) (Select this Option)

IMP GAL (for Imperial gallons)

To set unit press "Enter", which will also bring the operator back to the Calibration Mode Displayed.

NOTE: The operator can only return to the main menu via the sub- menu ''TOTAL"

PAGE 6 OF 14


5.2.1.5.6 "K-FACTOR"

The "K-FACTOR" is a function which is used to set or calibrate the Meter. The Flow Sensor can be used in different size pipes and therefore has to be set to the size pipe it is installed in.

There are two methods to accomplish this:

Use the "K-Factor" of the fitting which can be found on the "K-Factor" TABLE 5-1;

Use the "Teach-in" function.

We recommend that the TABLE 5-1 be used unless there is some question about the performance of the unit at which time the "Teach-In" method would be used. This method is also used for calibration.

Example:

In order to determine a quantity, the operator shall fill a Tank of a known amount (25 or 50 gallon Tank). When the message "TEACH YES" appears press "Enter" key to start measuring procedure at which time the "FILLED" will appear. The operator will then open up a Valve or switch the Pump "ON". As soon as the Tank is filled, switch "OFF" the Pump, or close the Valve. Pressing "Enter" stops the process. The operator will then be asked to enter the quantity (25 or 50 gals). The calculated "K-Factor" is displayed after confirmation.

The following steps are used to enter the "K-Factor" as per the TABLE 5-1:

1. K-FACTOR Press "Enter" Key;

2. TEACH NO Press "Enter" Key.

3. K=XXXX

From the "K-Factor" TABLE 5-1, and using the "Up/Down Arrow" keys enter the "KFactor".

Example:

For 1 - 1/2 inch, PVC pipe, the Impulse I US Gallon" K-Factor is 65.4.

Once the "K-Factor " is entered, press the "Enter" key which saves the number and returns the operator to the Calibration mode display.

PAGE 7 OF 14


5.2.1.5.7 OUTPUT CURRENT

This allows the operator to enter a measuring range of the flow corresponding to the 4 to 20 mA output.

From the Calibration mode press the "Down Arrow" key for Current:

1. CURRENT Press "Enter" Key;

2. 4=XXX.X

Using the "Up/Down Arrow" keys enter the beginning of the measuring range.

Press, "Enter" to set selected value:

3. 20=XXX.X

Using the "Up/Down Arrow" keys enter the end of the measuring range

Example:

To set for 0 at the low end and 200 GPM at the high end, the low measuring range would read "4 = 000.0 and 20 = 200.0" (If one decimal Point was selected).

5.2.1.5.8 PULSE OUTPUT

This menu allows the operator to enter the parameters of the pulse.

As an example one pulse could equal 5 US Gallons:

1. PULSE Press "Enter" Key;

2.

3.

4.

5.

6.

Using the "Up/Down Arrow" keys the operator can choose the engineering unit.

L (for liters)

M3 (cubic meters)

US GAL (for US gallons) (Select this Option)

IMP GAL (for Imperial gallons)

Press "Enter" Key.

PU=XXX.XX

Using the "Up/Down Arrow" keys enter the end of the measuring range input the quantity corresponding to one pulse and press "Enter" which sets the quantity and

PAGE 8 OF 14

---


returns the operator back to Calibration mode.

Example:

To set one pulse equal to 5.0 US Gallons, PU = 005.00

5.2.1.5.9 RELAY

The parameter definition of the limit contacts is done in this menu. Two limit values are entered for each Relay; 1- and 1 +or 2- and 2+.

The operator also has the possibility to invert the Relays. The unit and decimal place, as selected in the sub-menu "UNIT" are activated.

From the Calibration menu choose "RELAY":

1. RELAY Press "Enter" Key;

2. 1.=XXXX

USE THE "Up/Down Arrow" keys to enter a value and press "Enter":

3.a. INV NO If you do not want to invert press "Enter"/ or

3.b. INVYES If you want to invert press "Enter".

After pressing "Enter" the operator has the same options to set Relay No. 2. The procedure is the same. "Enter" sets the entries and returns the operator to Calibration menu.

5.2.1.5.10 FILTERFUNCTION

The dampening is specified in this sub-menu. It prevents fluctuations of the display and output current.

There are ten levels available. The first levei"FILTER" has no dampening effect. From the calibration menu choose "FILTER" function:

1. FILTER Press "Enter" Key;

Using the "Up/Down Arrow" keys to choose the amount of filtration.

2. FILTER 0

3. FILTER 9

Press the "Enter" key to set the selected filter and return to the Calibration menu. If "FILTER 0" is selected, it has no dampening effect.

PAGE 9 OF 14


5.2.1.5.11 TOTALIZER

This menu allows the operator to reset the main and daily Totalizers.

The reset procedure only starts when "Enter" is pressed, at the "END" position in the parameter definition.

From the Calibration menu choose "TOTALIZER":

1. TOTAL Press "Enter" Key;

Using the "Up/Down Arrow" keys to choose one of the following displays:

2.a. RES NO Do not set Totalizer to "0";

2.b. RES YES Set Totalizer to "0".

Press "Enter: to set Totalizer and to return to Calibration menu.

5.2.1.6 TEST MENU

From the main menu press the "Up Arrow", "Down Arrow" and "Enter" key simultaneously for (5) seconds. The following compensations and test are carried through in the sub-menus:

1. OFFSET Zero Compensation (4 mA);

2. SPAN Span compensation (20 mA);

3. FREQUENCY Indication of sensor frequency;

4. FLOW

5. END

5.2.1.6.1

Entering the flow rate to be simulated. The outputs will react in accordance to this input;

This function returns operator to main menu, and stores the new parameters for "OFFSET" and "SPAN". If one of the two values is erroneous, the device point on "OFFSET", and new values must be entered.

Use the "Down Arrow" key to choose a menu.

OFFSET COMPENSATION

This menu allows the operator the option to correct the basic setting of 4 mA. The operator only needs a current meter. When "Enter" is pressed while "OFF-SET" is

PAGE 10 OF 14

...

II!

II!

...

SIEMENS displayed, the Transmitter produces 4 rnA. corrected by entering the measured value.

Water Technologies

If this value is incorrect, it can be

From the Test Menu choose "OFFSET":

1. OFFSET Press "Enter" Key;

After "Enter" is pressed the Output will be displayed:

2. OF= x.xx

Enter the required value. If incorrect, use the "Up/Down Arrow" keys to enter the corrected value.

Press "Enter" to set I store the value and return to the main test menu.

5.2.1.6.2 SPAN COMPENSATION

In menu the operator has the option to correct the basic adjustment of 20 rnA. The procedure is identical to the "OFFSET" procedure. When "Enter" is pressed while "SPAN" is indicated, the Transmitter produces 20 rnA. If this value is incorrect, it can be corrected by entering the measured value.

From the test menu choose "SPAN COMPENSATION":

1. SPAN Press "Enter" Key;


2. SPAN = xx.xx

If incorrect use the "Up/Down Arrow" keys to enter the correct value.

Press "Enter" to set the value and return to the main test menu.

5.2.1.6.3 FREQUENCY DISPLAY

This menu allows the operator to observe the Sensor frequency until the "Enter" key is pressed. No changes to the unit are made from this menu.

From the test menu choose "FREQUENCY DISPLAY" :

1. FREQUENCY Press "Enter" Key;


2. xxx.x HZ

PAGE 11 OF 14


Press "Enter" to return to the Test Menu.

5.2.1.6.4 FLOW SIMULATION

The operator can simulate flow in this menu. This allows the operator to test the system without any liquid. Even though the simulated value influences the Output current and the Relays, it has no impact on the pulse output. Unit and decimal place, as selected in the sub-menu "UNIT" are active.

From the test menu choose "FLOW SIMULATION"

1. FLOW Press "Enter" Key;


2. xxx.xGPM

5.2.1.7

After the Flow is displayed enter flow value with the "Up/Down Arrow". The simulation is active unit the user enters into another submenu or returns to the main menu.

DISASSEMBLY and ASSEMBLY OF FLOW TRANSMITTER

(Refer to FIGURE 5.1 at the end of this Section)

1. Remove all power to the Generator by turning the Power Supply's Main Disconnect DS1 (or Main Circuit Breaker CB1 -if available-) "OFF";

2. To open connector remove screws and remove external connector from internal connector;

3. Un-tighten plastic nut from housing and remove Transmitter;

4. To install Transmitter reverse the above steps.

NOTE: When the Transmitter is properly installed, the Transmitter cannot be rotated.

5.2.2 DISPERSAL PIPE

The Titanium dispersal pipe is used for mixing of the Hypochlorite in sea chest. This piping should be 1" in diameter, Schedule 80 pipe, supported by a bracket at one end and a flanged penetration pipe at the other end. The pipe has several evenly holes at various points for Hypochlorite's dispersal.

Upon installing, this pipe must be thoroughly checked for tightness. It is subject to high velocities of water and vibrations and will suffer damage if not made rigid at installation.

PAGE 12 OF 14


5.2.3 STRAINER

The Strainer is provided to remove unwanted particles from the Inlet sea water. The Strainer consist of a 1 - 1/2 inch CPVC body, an "0" -ring, Strainer Screen Basket and 1/16 inch Screen Mesh. See FIGURE 5-2 at the end of this Section.

5.2.4 CIRCULATION PUMP

The purpose of the Circulating Pump is to increase water flow because 25 GPM is the minimum requirement for the CHLOROPAc® generating system. Separate controller is used to operate this pump. Refer to circulating pump manufacturer's manual and installation drawings located at the end of this section.

5.2.5 OUTLET FLOW METER ASSEMBLY

The outlet flowmeter assembly consists of flow indicator and diaphragm valve. This Flow indicator is located on outlet side of generator to one of the sea chest to balance the flow between two sea chests.

5.3 INLET/OUTLET ASSEMBLIES DRAWINGS

PAGE 13 OF 14


DN Specific Fitting "K Factor" (impulse/1) ~·

mm Inch Brass PVC pp PVDF

15 1/2 112.90 107.60 112.90 112.90 till

20 3/4 65.69 76.14 79.10 79.31 ""

25 1 49.41 53.93 56.72 57.17 .. ...,,

32 1-1/4 27.12 28.49 30.04 31.49

• 40 1-1/2 18.47 17.28 18.44 18.88

50 2 10.65 10.07 10.69 10.71 Ill'

.. DN Specific Fitting "K Factor" (impulse/US gal)

Ill!

mm Inch Brass PVC pp PVDF

15 1/2 427.6 407.2 427.6 427.6 • ''" 20 3/4 248.7 288.2 299.4 299.8 lillie

25 187.0 204.1 214.7 216.1

32 1-1/4 102.7 107.8 113.7 119.0 IIi

40 1-1/2 69.9 65.4 69.8 71.4

50 2 40.3 38.1 40.5 40.5 1111'

""' Notes:

1111'·

1. The "K Factor" (specific fitting Factor) has been measured on a certified rig with water at 20 degrees C. and a flow velocity of 2 m/s (6.56 Ft/s). This "K Factor"

n the installation conditions. eatabil is better than 0.4%. II-'>

2. Imperial Gallons: "K Factor (impulse/lmpgal = 4.55 x "K Factor"

Of·

PAGE 14 OF 14

....!=).{~QI~~ F.F. FLANGE (TYP)

---- FLow----- -+-~-------

PROGRAMMING OF FLOWMETER ENTER ~ENU TO ENTER THE lotENU ON THE FlO'MAETER PRESS "DOWN ARROW" KEY AND "ENTER'" KEYS SIMULTANEOUSLY FOR 5 SECONDS.

~ENU ITE~S USE THE "DOWN ARROW" KEY TO SCROll. THROUGH THE UENU AND "ENTER" TO ACCESS MENU FEAlURES.

DATA SETTINGS USE THE "UP ARROW" AND "00'1\'N ARROW" KE't'S TO MANIPULATE DATA AND "ENTER" TO SET DATA.

SETTINGS LANGUAGE : SET TO ENGUSH

K-FAC~~ ~ ~ ~g ~~~OR PVC 1-1/2" PIPE CURRENT : NOT APPUCABLE

PULSE : NOT APPUCABLE RELAY : SET 1- TO 24.5

SET 1+ TO 25.0 SET 1 INVERT TO NO SET 2- TO 24.5 SET 2+ TO 25.0 SET 2 INVERT TO YES

ALTER : SET TO 8 TOTAL : NOT APPUCABLE CODE : NOT APPUCABLE

END : PRESS ENTER TO LEAVE MENU t.AODE

~-.... ""'"" SUPPI.Y

Q '-v-' OPEN: NORtr.lAL F\..OW CF'EN: LOW FlOW

CLOSE: LOW FLOW a.OSE: NORWAL FlOW

WIRING DIAGRAM "WARNING"

F~E~l:&~tr~~N3J~

3

RECOUUENDED BOLT TORQUE IS 12ft. lbs •

"A"

= PLUG ONE PORT WHEN NOT USING BOTH, TO PREVENT DAMAGE TO S'MTCH.

BURKERT QUARTER TURN CONNECTION

= 1. ~~~NTH~EB~~TON~~~gw~ l?o~RJOe~~O"FITllNG ITEM f2.

2. TIGHTEN THE ELEClRCtiiiC HOUSING WllH TI-lE SET SCREW A. 3. ASSEI.!BUEO WEIGHT IS 2.5kg (5.51b).

~ I I

~-------

CUSTOMER'S 7---SEACHEST

6" [152mm]

I 23 i"

[520mm]

~ I -fE!F• -------Fj-~---__1_

1--____ 36" [914] ____ _

REQUIRED

f I I ! ' . ' ' . I' •

72"

REQUIRED

f 1 ' ' ' ' ' '

¢0.625" [¢15.8mm] ¢3.875"

[¢98.4mm]

¢1.95" __; ·1

"------ ¢5" [049.5mm] [¢127mm]

SECTION A-A

If I f I f • I

OUTL£T

n

r- f"~l I ~~ • 132 [s,i·l I WTG. f-1-0

L...

--------------------------. &

r--------- [1s ... ·1 I 327 [1286.]

a.EARENCE FOR BASKET RDIOVAL 1-------343 1132"1 I

,~

' 1 $ ,,,

®-

1!2

ALTERNATE OUTlET

~ I I 1-112· 1501b

IINlL£T 39 r-+4 [152"1 ANSI FlANGES

1 340 [13i"l

241 1•2"1 -, 1~J;(.•~,;;~r 83 !"i"l

I I I I I 1•1f!·1r-ll= I ~ 1312·1J L 12~1~r~-- 17 1/,!·1

156 1•a·1---

" =o ~ U.S.C.G.

INSTALLATIONS

APPROVALS HUll N01IWO NO

A jiNillAL RElEASE

.....

5 1 4 1 3 1 2 1 1 1

ITEM QTY

~1:.

STRAINER BASKET CLEANING INSTRUCTIONS

1. DE-ENERGIZE CHLORa"AC SYSTEM.

2. CLOSE ISOLAllON VAL\!t:S TO STRAINER OR CHLOROPAC SYSTEM.

3. DRAIN STRAINER BY REI.t0\11NG 10 [3/8•] PLUG.

4. REMOVE GASKETEO STRAINER CAP BY TURNING HANDLES (LOCA TEO ON ITEM 1) COUNTER-CLOCK'MS£.

5. REt.AOIJE BASKET (ITEM 4).

6. CLEAN BASKET AND INSPECT SCREEN FOR WEAR.

7. CHECK STRAINER BODY FOR (ITEM 3) FOR DEBRIS & WEAR.

8. REPLACE CLEANED BASKET.

9. TIGHTEN STRAINER CAP BY HAND UNlll SEa.JRE.

10. RUN SEAWATER lHROUGH a-ILOROPAC SYSTEM FOR 10 MINUTES AND INSPECT STRAINER FOR LEAKS,

11. ENERGIZE CHLOROPAC SYSTEM TO RESUME NORt.!Al OPERATION.

12. ASSEt.4BUED 'IYEIGHT IS 7.5kg (16.51b).

DRAIN PLUG. 3/8" NPT 7.3485-002-05 CPVC HAYWARD

BASKET, 1/16" f HOLES 73485 002 04 316SS HAYWARD

BODY 73485 002 33 CPVC HAYWARD

0 RING 73485 002 02 'J1TON HAYWARD COVER 73485 002 01 CPVC HAYWARD

DESCRIPTION PART No. MAT'L. MFG.

LIST OF MATERIAL

73485-002-05 73485-002 04

73485 002 33

73485-002 02

73485-002 01

MFG. No.

-- llaiOIG llMt mu INSTALLAllON DRAWING

~..::;,;ee a!- ::-w ~.fciff5a"C:Js~~~ ~~>PIN 7J<ta5-oo2-JO =~...::nr:~~.m=~"":.,~,......:::'-$mi~~~

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CD PRESSURE PORT 1 I 4"NPT \ _C 0_ \ PORTS Q) & @ARE EXHAUST PORTS

.......--ri -'---L.I

246 [9~ "]

NOTES:

JRE TO PORT CD . 1 . CONNECT PRESS

2. EXHAUST PORTS CAN BE LEFT OPEN.

120VAC SOLENOID VALVE

I~!:.I'U ~'!:. ~D·~ Ill GND

I 1WVAc' INPUT

WIRING DIAGRAM

f ! ' I '

\ \ \ ~

-'-!.! ~

~ ru I I

I I

,----

~+~ n - - ~INLET

L165 [61"J

u

KACE BALL VALVE, HASTELLOY C BODY WEIGHT: 2.2kg [27.81b]

A IINillAL RELEASE REV DESCRf'TION

B-7-091 JLM I I CVP DI.TE lWI'N CHKD

f • I • ' I ~ ' I

lh---, I~

127 [5"]

BY

MAR AD

A. B.S.

U.S.C.G.

OWNERS

!1>16 [~"]

!1>99 [¢3§"J

APPROVALS HULL NO APPROVAL I 11£S1.811TDA'IE

Lllt.NO. I DA'IE

_, .. ... ~

INSTALLATIONS f----------+--------+----1

~ ' f

DATE

8-7-09

DATE 8-7-09

'I

l1TLE INSTALLATION DRA'MNG M.G.P.S. (ANTIFOUUNG DEVICE) BALL VALVE W/ACT. 1-1/2" FLGD. HAST.C P /N GBA04160

CUENT MSC

""""" REV

2429590-A3-G14-10 A

' • ... " ;:


SECTION VI

INSTALLATION

6.1 GENERAL

The CHLOROPAC® Generators and Power Supplies are individually pre-assembled and shipped as separate units.

The installation procedure consist of properly securing the Generator and Power Supply Assemblies, installing the interconnecting wiring, and attaching the Inlet and Outlet piping to the Generator.

6.2 GENERATOR

The Generator shall be installed in a horizontal position, with the Inlet and Outlet piping parallel to the deck (horizontal).

The Generator must be installed with sufficient clearance on all sides to permit installation, operation, servicing and removal.

The Generator Assembly must be secured in place by four mounting screws in the bottom of the Assembly case.

It is extremely important that, before any water or power is turned "ON", all hardware must be checked and tightened to the following:

);> Generator Cell hardware: 1 0 lb-ft /1/4 kg-m;

);> All electrical connections: 20 lb-ft /2.8 kg-m.

6.2.1 GENERATOR PIPE CONNECTIONS

The Generator Assembly is fitted with two 1 - 1/2 inch IPS Titanium pip flanges.

These flanges are spaced 8 inches apart and are 4- 1/2 inch above the bottom of the Assembly case.

Facing the flanges, the Inlet of the Generator is on the left and the Outlet is on the right. The Inlet piping may be of any material suitable for sea water service. The Outward piping should be SARAN lined steel or other material suitable for weak Sodium Hypochlorite service.

Neoprene 1 - 1/2 inch gaskets are recommended between mating flanges.

PAGE 1 OF 7


The flow rate through the Generator Assembly should be at least 25 GPM and the Inlet pressure should be between 15 and 100 PSI.

The flange hardware should be 1/2 inch stainless steel bolts and nuts with corresponding washers and lock washers and torqued to 1 0 lb-ft (1.4 kg-m).

6.2.2 DISPERSAL PIPE

A dispersal pipe should be installed in the water box to prevent high concentrations of Sodium Hypochlorite from attacking the piping or the tubes. A Dispersal pipe will insure proper mixing of Sodium Hypochlorite and water which prevents this corrosive attack.

A dispersal pipe may be as designed by SIEMENS but manufactured by the installing facility.

When installing a dispersal pipe, the hole must be free from debris, the pipe and penetration valve must be SARAN line steel or an equally chemically resistant material. All welded supports should be of the same material as the water box, and as close to the outboard side as possible.

6.3 POWER SUPPLY

The Power Supply, 4 lbs./h and smaller, shall be installed in a vertical position, on a wall or dedicated structure, with the Incoming and Outgoing wiring located at the bottom of The Enclosure.

The Power Supply must be installed with sufficient clearance on all sides to permit installation, operation, servicing and removal. The Enclosure cooling air circulation shall not be restricted by any obstruction.

The Power Supply Assembly must be secured in place by four mounting screws in the frame of the Assembly case.

It is extremely important that; before any power is turned "ON", all hardware must be checked and tightened to the following:

Power Supply hardware: 10 lb-ft/1.4 kg-m;

Y All electrical connections: 20 lb-ft I 2.8 kg-m.

6.4 ELECTRICAL CONNECTIONS

The CHLOROPAc® Equipment components must be Field interconnected. The size of the interconnecting wiring should be as specified below.

PAGE20F7

...

..

•


All CHLOROPAc® Equipment electrical connection should be made through access plates located and drilled for electrical bushing or stuffing tubes for the connecting wiring at the rear of the Generator Assembly, and at the bottom of the Power Supply.

All wires should have sufficient insulation cut away on the ends to allow for connecting to the proper terminals

All electrical bolt connections shall be torqued to 20 lb-ft (2.8 kg-m).

6.4.1 INCOMING AC POWER WIRING

The incoming AC, 60 Hz, single Phase power feeder must be connected to the Power Supply Cabinet as follow:

~ On Saturable Reactor Type Power Supplies to Main Circuit Breaker CB1, Terminals L 1, L2 and GND (Ground if supplied).

The Incoming AC, 50/60 Hz, 3-Phase Power Feeder must be connected to the Power Supply Cabinet as follows:

~ On Switching Type Power Supplies to Main Disconnect DS1, Terminals A, B, C and GND (Ground if supplied).

~ On Saturable Reactor Type Power Supplies to Main Circuit Breaker CB1, Terminals L 1, L2, L3 and GND (Ground if supplied).

The Power Incoming conductors should be sized for continuous (1 00% duty) service.

The Power Feeder conductor size should be as follows:

~ On 1/2 lb/h to 4 lbs/h Power Supplies a minimum of #1 0 AWG (6 mm2).

This conductor size, in free air, at an ambient temperature of 30° C (86 F), is rated 30° Amperes AC.

~ On 6 lbs/h Power Supply a mm1mum of #8 AWG (1 Omm2). This conductor size, in free air, at an ambient temperature of 30 C (86 F), is rated 50 Amperes AC.

The Maximum Feeder length for each rated Power Supply is shown on TABLE 6-1 in this Section.

If a greater Feeder length is required, or a smaller Feeder Voltage Drop is required, the next standard size conductor, in free air, will increase the distances shown in the Table, or decrease the Feeder Voltage Drop.

PAGE30F7


MAXIMUM FEEDER LENGTH FOR 5% FEEDER VOLT DROP System Unit Maximum Maximum Protective Maximum Voltage Rating Volt Drop Device Feeder Length

lbs/h Size for #10 AWG (6mm 2)

kVA AC Feet Meter Current

120V 112 6V 2.85 23.8 35A 200 61 1 6V 4.66 38.88 50 A 121 37 112 2.08 3.16 4520 1377 1 4.19 6.32

20A 2260 689

1* 3.60 5.47 2611 796 38V

2 18V

7.20 10.94 1305 398 4 14.40 21.88 30A 652 199 6** 21.60 32.81 40A 678** 199 112 2.08 3.16 4520 1377 1 4.19 6.32

20A 2260 689

1* 3.60 5.47 2611 796 460V

2 23 v

720 10.94 1305 398 4 14.40 21.88 30A 652 199 6** 21.60 32.81 40A 678** 206**

*=UK Rating **= 6 lbslh Saturable Reactor Type (Minimum Conductor Size to be #8 AWG (1 0 mm2).

NOTE: If Maximum Voltage Drop other than 5% is required, find out the Maximum Feeder Length by multiplying the existing length by the ratio of the New Maximum Voltage Drop required to existing 5 %Voltage Drop. (e.g. For 2% Maximum Feeder Voltage Drop, and 2 lbs I h Power Supply operating at 380 V AC, the Maximum Feeder Length = 1305 Ft x (2% I 5%) = 522 Ft (159 m).

Table 6-1

6.4.2 CONTROL AND INSTRUMENTATION WIRING

Where CHLOROPAc® Equipment interconnecting cables are required, these should be a minimum of:

Y ,#14 AWG (2.5mm 2) for control wiring;

Y #16 AWG (1.5mm 2), shielded, for instrumentation wiring.

The ends of these cables should have sufficient insulation cut away to facilitate secure connection to the Interconnecting Terminal Blocks. The interconnecting wires (wire color, wire number, etc.) shall be as specified on the Installation Drawing Diagram at the end of this Section.

PAGE40F7

''"

...

...

-

...

...


The Leak Detection Wiring must be connected between the Generator Terminal Block, terminals 5, 6 and:

>- On Switching Power supply Terminal Block TB 102, terminals 8 and 9, or

>- On Saturable Reactor Power Supply Terminal Block, terminals 5 and 6.

The shield of the shielded cable must be terminated to a grounded terminal at the Power Supply side only.

The Flow Detection Wiring must be connected between the Flow Transmitter Assembly (located on the Generator Seawater Inlet piping) and the Power Supply Terminal Block TB 102, as follows;

6.4.2.1 The 120 VAC supply power to the Transmitter electronics:

1. This HOT/LINE wire: between Transmitter terminal L 1 and

>- On Switching Power Supply Terminal12 or

>- On Saturable Reactor Power Supply Terminal1 0;

2. The NEUTRAL wire: between Transmitter terminal Nand

>- On Switching Power Supply terminal13, or

>- On Saturable Reactor Power Supply terminal 9.

3. The GROUND wire: between Transmitter Ground terminal GND and:

On Switching Power Supply terminal11, or

On Saturable Reactor Power Supply terminal GND.

6.4.2.2 The Flow Status signaling by the Transmitter Flow Relay:

1. The COMMON Relay terminal wire: between Transmitter terminalS and:

On Switching Power Supply terminal 5, or

On Saturable Reactor Power Supply terminal 3.

2. The LOW FLOW/NORMALLY CLOSED Relay terminal wire: between Transmitter terminal 7 and:

>- On Switching Power Supply terminal 7, or

>- On Saturable Reactor Power Supply terminal?.

PAGESOF7


The NORMAL FLOW/NORMALLY OPEN Relay terminal wire: between Transmitter terminal 9 and:

3.

4. On Switching Power Supply terminal 6, or

5. On Saturable Reactor Power Supply terminal 4.

6.4.3 DC POWER WIRING

Power Supply POSITIVE (+) Terminals P1/P2 must be connected to the Generator POSITIVE(+) Terminals.

Power Supply NEGATIVE (-) Terminals N1/N2 must be connected to the Generator NEGATIVE (-)Terminals.

WHEN DISCONNECTED FOR SERVICE, THESE LEADS MUST NOT BE REVERSED.

In order to insure that the Cells connected to the Power Supply deliver their designated/rated output, the load cables should be selected so that there will be as little Voltage Drop as possible.

To insure efficient operation, the Voltage Drop between the Power Supply and the CHLOROPAc® Generator on each conductor should be less then one volt;

(Total of 2 volts; -1 volt on the Positive lead; 1 volt on the Negative lead).

See Table 6-2 in this Section for DC wires sizing and the Cable Voltage Drop.

ZERO TO ONE VOLT DROP CHART WIRE SIZE MAXIMUM LENGTH FOR ONE VOLT DROP AT 100 AMPERES DC #2 AWG I

56 Ft.l17 m 35mm 2

#1IOAWGI 89Ft./ 27m

50mm 2

# 210 112Ft./ 34m

AWGI70mm 2

#4IOAWGI 179Ft./ 55 m

90mm 2

Notes: 1 . To calculate the Maximum 1 Volt Drop Length for other than 100 Amps DC, multiply the above lengths by the Ratio of 100 Amps I New Amps.

(e.g. At 225 ADC, using 210 AWGI 70 mm 2 cable the Maximum Length is: 112 Ft. x (1 00 ADC I 225 ADC) = 50 Ft./ 15.25m); 2. The Maximum current carrying capacity of a #2 AWG/ 35 mm2

copper conductor in a 50 degree C ambient temperature is 155 Amps. Do not use #2 AWG/35mm 2 to carry more than 155 ADC.

TABLE 6-2

PAGE 6 OF 7


6.5 INSTALLATION SERVICE

The use of a service engineer for initial installation is highly recommended.

This recommendation is made for several reasons:

1. Assurance of proper operation from the outset:

2. Experienced supervision will cut installation time drastically;

3. Proper training of operating personnel is afforded.

6.6 INSTALLATION DRAWINGS

PAGE70F7

' ~ 11

+40VAC/JPH/60Hz 30A

' ' 'f 1 2 3

PS-1 POWER SUPPLY

(-) (+) (+) (-)

I I I I I I I I I I I I

120VAC/3PH/60Hz

~~ 'Y'

1 2 3

SCP-1 SYSTEM

CONTROL PANEL

----, I I I I I I I I I I I I I I I I I

r-------..1 I I I I L-------, I

I I I I

I

()

I I

(+) (+)

G-1 CHLOROPAC GENERATOR

SB2K

L-rn--m-~~-,

I I

I I I I I I I I I I I

~Z,-rn m-J

C-1

N

r--"'T'"---..-·~~

''''"" A:B.S:-u.s.c:G:'

INSTALLATIONS

I '

BV-4 ~BV-5

BFA ANALYlER BFAOOOOOO

APPROVALS

..... :=-r ... r--

' ~

BV-6

'

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I 1 ry 3 l_ _____ 1

HUll. NO! IIIlO NO

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CUOO A/S CUENT A/S

r---1 SV-2 I I

~ r--+-----1 \---tk1-----t : DSP-1

I I I

i ~ ----------~-----------~ ----------~-------------------------~-------------------------~-----------,

CUENT A/S

y I J, I '' I 120VAC/1PH : /60Hz

I I I I I I I I

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SV-4

~ 1--------11---!>i:J------DSP-J

' f ' II '

HIGH SEACHEST

r-~,~~~4 I

I-~--~

r-~ r ',~p6~4

r-~,~~~4 I

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sc~-,Y.-1 DISTIU£D~11624

r-t------1---~r ...... o\im I

sc~-,Y.-OIS'Tlli.ED FEED Put.F 2

r-t------1---~1~~4

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r-~,~P"~4 I

s~_,tr-

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r-r------1---~1 tp'i~4 I sc"W_,Y--

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LOW SEACHEST

~1~p6~4

scW_,Y.-

.l.EliWil fl FlOW INDICATOR FSL FlOW SWITCH LOW I INTERLOCK l.AH l.£VEl. ALARM HIGH LSH LEVEL SWITCH HIGH ZSC Ut.AIT SWITCH CLOSED ZSO Ut.AIT SWITCH OPEN XA UNIT ALARM

-~~ ""' INSTALLATION DRAWING ;:._ :;a' PIPING AND INSTRUMENTATION DIAGRAM

,_._., - MSC-T-AKE (MMR)

'I! f • • I w ' I '

ICI

!

I ' If 111

n

1------ 22(s" [564]-----

FRONT VIEW (INTERIOR)

f"..- I'-

..r

_e~"[149] i l 15. [381]

CENTER Of GRA'flJY FROU BOITOU OF FRONT DOOR APPRO.UAlE \\f:IGHT: 651b (29kg)

APPROVALS HULl NOIIIIO NO

IIAAAD A:B:S:'""

INSTALLATIONS

~~"[230]-1

D~--,.,

SIDE VIEW

24. [610]

I 22j" [572] 1-i"[\9

.,....-- ~ 0

~ L"

[ SIEMENS ~ ~:~~:~

= [;;&;] @

• • >,\" 31,\"

... "' !40] [802]

.-:1 30"

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'""

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[Kl 01 10

'------~ l±l i"[19]J

~r. •10] I.ITG. .HOI..£4 PlCS

FRONT VIEW (EXTERIOR)

QES!GN ANQ PERFJRMANCE QAIA

INPUT VOLTAGE: 120VAC ±5%/11/SOHz ±SX INPUT kVA: 1.8 ~AX

OUlPUT PO\\f:R: 4-20mA CONSTRUCTION: WALL OR BULKHEAD MOUNTED ENQOSURE CONSTRUCTION TO IP-23. ALARM CONTACT RATING: O.SA, 125VAC

FUSE DATA: INPUT: FU-307 15A. P/N 80116-001 FU-315 3A. P/N 54273-006 CONTROL: FU-318 10A, P/N 54273-010

~mu: INSTALLATION DRAWING

IA.G.P.S. (ANll-FOUUNG DEVICE) 3-S-11111 SY'SlBI COOTRCl. PANEL ASSEMBLY P~ ECP03000-001

~ctDr t.ISC-T-AKE ........

-2429590-A1-G14-02 "' A

1 ~ I

1----------,.. [737]---------1 1-------- 21" [686] •m-------

-------------, ~- I I~ I 1®~-1 ~I 1@~1 I I I I I

I

9/16• [14] OIA HOLE THRU (4) REQD

==HSTATUS LAMPS ~ AMP&VOLTA.GE

.. METERS

I LOW&: NORMAL • FLOW INDICA TlON

L _____ _

.~GE [ ""«-:,..,.., .,.,..,:uom lj AIR FLOW

_j

tllliESc

1. AllOW 24 INQ-IES FREE SPACE ABOVE A/ID BELOW, ENCLOSURE f"(~ CONYECllON COOUNG OF FINNED HEAT SINKS.

l.EAIC OElECllON STATUS LAMPS

AUTO t.tAMJAL SEL!CTOR SWITCH WANUAL &: a.JRRENT UI.IIT ADJJST POlrNTlaETERS LEAK DETECTOR RESET

SECURITY DOOR FASTENER TYP.

2. All ELECTRICAL CABL£S ENTER THROUGi BOTTDIII OF PO'A£R SUPPLY.

J. UNSIZED CONDUCTORS 10 BE t.IINIMUM 16AWG (U5rM'12)

4. RENO'v£ JJNPER FROU PINS 2 1U 3 ON TB102 WHEN USING AN EXTERNAL 4-20mA COHTROL SIGNAL JJt.tPER ~STALLED fOR PUMP SVIl~ING Of>ERATlON.

5. FOR SPARE PARTS UST REFER TO 1.4AINlENANCE AND (J>ERAliONS 1.4ANUAL

lei ,------,,------, I I ,------,,------, ,------,,------, I I ,------,,------, ,------,,------, I I ,------,,------, ,------,,------, lh I AIR ,------,,------,

~ ,------,,------, I lVI ,------,,------, ,------,,------, I 1/\1 ,------,,------, ,------,,------, IF-l ,------,,------, ,------,,------, II ,------,,------, ,------,,------, II .,------, r-Jo ,------,,------, II ,------,,------, ,------,,------, 1•1 ,------,,------, ,------,,------, u ,------,,------, ,------,,------, ,------,,------, ,------,,------,

~ ,------,,------, ,------,,------, ,------,,------, ,------,,------, ,------,,------, ,------,,------, ,------,,------,

I

,------,,------,

1/4-20 X 3/4" [19).j GROUND STUD

CABLE TERMINA]ON DIAGRAM N.T.S.

APPROVALS IIULl NO IIWO NO

"" iiAAAD ~ U.S.C.G. .,... ... INSTALLATIONS A I ISSUED FOR REV£W

J ' ' ' f I • I I 'J ' ' •

DESIGN AND PERFORMANCE QAT A

INPUT VOLTAGE: 460VAC ±10%/3*/SOHz ±SX

INPUT kVA: 13.8 MAX

OUTPUT POWER: 450AOC, 28WC, 12.6kW (MAX AT SO'C AMBIENT m.tP.)

CONSTRUCTION: WALL OR BULKHEAD MOUNTED ENCLOSURE CONSTRUCTION TO IP-23.

AlARM CONTACT RATING: 0.6A, 125VAC

0

<M'I<M'

t '

FUSE DATA: INPUT: F1, F2, F3, 30A, P~ 74666-012 CONTRCL.o F4, 2A, P/N 74666-013 OUTPUT' (2) DC FUSES PER GENERATOR CELL, FS, F6, 250ADC, P/N 55658-250

APPUCATlON: 50682-004SW-02 POWER SUPPLY FOR 41b/h WITH 26 VOLTS ON GENERATOR TERMINALS. VOLTAGE DROP NOT EXCEED 2 VOLTS.

FRot.l BOTTOI.4 ($ FRONT DOOR APPROXII.IATE WEJGHT: 2351b (107kg)

18[457]

~STAli.ATION DRAWING

t.t.G.P.S. (ANTl-FOUUNG DE'VlCE) OiliER SUPf'L Y, 460/3/80, 450/28, P2J, P /N 50682-004SW-02 .......

' ' ' •

fiWEICI.IDIT t.ISC-T-AKE ........

'!' ' ' '

-2429590-A 1-G14-03

~ I .. ' ' s

DESIGN AND RfffRfNCf DATA

INPUT VOLTAGE: 26-28\/DC, 0-450ADC SEAWATER FLOW RAl£: 20-32gpm 0 25-100psl

CAPACITY: 41b/h lolA)( SODIUU HYPOCHLORilE 0 LOAD RATINGS OF 28\IDC, 450ADC IN SEAWATER

lE'-1PER."TURE: 0-SS"C CONSTRUCTION: DECK UOUNTED ENCLOSURE 304SS

WltS:. 1. (1) VOLT MAX DROP ACCROSS WIRE LENGTI-1 PER LEAD.

1B!" [460]

OUTLET u

1-1/2"(38] 150lB ~ ANSI F.F.

FlANGE ('NP)

0 I '

i• P"l

I 16j"

~r 18"

[457]

17/32,. [13] DIA. t.tTG HOLES (4 PLACES)

L~ '11 ~ ~ I - ~'"-CUSTOMER 1 S 1 4-v---, ACCESS PANEl

CENTER OF GRAVITY WEIGHT= 2701b [122.7kg]

""""' A:B.S:"'"

INSTALLATIONS

20 24 22 20 18 16

gpm14

12 10

• •

PRESSURE DROP 25gpm • 8.6psl

01234567 800

psi (OPERATING AT FULL OUTPUT)

APPROVALS !HUll NOliWO NO

A 1 ISSUED FOR REVIEW

41b/h GENERATOR

~1:.1=1= -2429590-A 1 -G14-04 "" A

J l ~

•a· (124]

1----<!· [124]----

lie le e;:,& ~ .I ~

FRONT VIEW !iNTERIOR)

- 1j"[28]1

I /6

§

7j· •i• 190] [171]

§

,o

·~· [151!]

•• [102]

I o\

§

0 I E-STOP I

§

OJ

·~· [151

MTG. HOLE riP. 4

1-----·11;· (157]-----1

1---·!· [109]---1

SIDE VIEW)


I

r2· (51]

" WAR~ u:s:-U.S.C.G.

""" ......

.. r 3"[76]

1 l

CENJFR Of GRAVITY

FROM BOTTa..l OF FRONT DOOR APPROX1UA1E v.EIGHT' 1!>b (7kg)

APPROVALS

""""" INSTALLATIONS

' f ' '

HULL NOI .. O NO

• ~ '"

B I E-STOP P/N CtW«3ED TO EsroJODO

A ISSUED FOR R£111EW

' ' •

DESIGN AND pERfORMANCE DATA INPUT VOLTAGE: 120VAC ±5X/1f/60Hz ±5"

INPUT VA: 20.2 UAX CONSTRUCTION: WALL OR BULKHEAD t.40UNTED ENClOSURE CONSTRUCTION TO IP-56.

• ~ • f! ~ ~

mu: INSTALLATION DRA'MNG 1.u I,___ I M.G.P.S. (AN11-FOUUNG DE'v1CE) ~ E-STOP ASSEUBLY P/N EST03000

Cdll1' lotSC-T-AKE

' 1 ~ '

-2429590-A 1-G14-05

J

... •

' 'Ill

16 1§1

82:4 794

[32(s1 [31i1 ..,-c.

762 [301

"20

"20

0 0

•

• t------610 [2411------

[~~ 1----11 (.441 OIA .IITG. HOLE ( 4 PLCS)

TB-2

OlmlliEJ

FRONT VIEW DOOR RD.l0\1£0 f-OR CL.Af(IIY

APPROVALS

INSTALLATIONS

1-1/2• 150# FF

OUTLET 1 152 [61

FF

432 ft71

1-1/2• 150# FF INLET l

91 [3fl:1 t

Hill NO

FIELD WIRING .... I.,.. BFA SIDE LT-1

TB1 10Vac 220Voc A2 V 81 (SIDE 1) BU<

Ill I .B1 1~ WHT

110VAC,60HZ,1¢ l>l>f-'--""'f T~~BUSBAR G-1 ,LT-2

, : CB2 SW2 w :

~~ 10 : -"':'-..IC!~,u<c..•!L.~-::_-"~"'t--1-,1 220VAC,60HZ,2¢ I ' I ' t-'-----<> 2A •

339[13/i;1--~ 192 [7fs1-

l 89 - [~1

SIDE VIEW

I 152 [61

TB2

TO BUSBAR G-1

PR-1

t~~.n: m£ NSTAI..l.A110N DRAWNG

~ ~ ~~~p~looooo-ftWK1 ......... _ flofl1l: WSC-T-AKE

2429590-A1-G1 4-06 "' A

IDI

'fr

' ..

' f

I ~ ~ 571 ---+-------j ,., I 3

RECOMMENDED BOLT TORQUE IS 12ft. lbs.

__1_.=_1[~QI~~ F.F. FLANGE (TYP)

----FLow---- -~--~-------

'

PROGRAMMING OF FLOWMETER ENTER MENU TO ENTER THE UENU ON THE F'LOWETER PRESS LlO'IIN ARROW" KEY AND "ENTER" KEYS SIMULTANEOUSLY FOR 5 SECONDS.

MENU ITEMS USE THE "DOWN ARROW" KEY TO SCROll. THROUGH THE MENU AND "ENTER" TO ACCESS WENU FEA lURES.

DATA SETTINGS USE THE "UP ARROW" AND "DO""" ARROW" KEYS TO MANIPULATE DATA AND "ENTER" TO SET DATA.

SETTINGS LANGUAGE : SET TO ENGLISH

K-FA~': ~ ~ ~g ~~~OR PVC 1-1/2" PIPE CURRENT : NOT APPliCABLE

PULSE : NOT APPLICABLE RELAY : SET 1- TO 24.5

SET 1+ TO 25.0 SET 1 INVERT TO NO SET 2- TO 24.5 SET 2+ TO 25.0 SET 2 INVERT TO YES

AlTER : SET TO 8 TOTAL : NOT APPliCABLE CODE : NOT APPliCABLE

END : PRESS ENTER TO LEAVE UENU MODE

APPROVALS

' '

" """;;;-~ U.S.C.G. OWNERS

INSTALLATIONS

, I ' • ' . '

~~ • .. :TOt mIN POSillON A~ FOR V!!J8NG AS SHOVIW '-......_

~WP lERMINALS 1M-lEN 4-20mA SIGNAL IS NOT REQUIRED

Q L..,-1 OPEN: NORtoiAL FlOW OPEN: LOW FLOW

Q.OSE: LOW FLOW a..QS£: NORMAL noW


F st'f~~~~tt~t~E~w~W"

HULl MOIIIIO NO

• f • "

2 2

1 1 ITEt.jQTY

' t • f

= PWG ONE PORT WHEN NOT USING BOTH, TO PREVENT DAMAGE TO SWITCH.

"A"

FUNGE, SOCKET 1-1 /2" UNION W/PADOl£ 1-1/2" TRANSMITTER, FLOW DIGITAL


=:_

,_ L~~NTH~Es~~ON~~~gw~ ~~~RJos~~flTllNG ITEM 12.

2 TIGHTEN THE ELECTRONIC HOUSING WITH TI-lE SET SCREW A.

3. ASSEWBUED 'l'tEIGHT IS 2.~g (5.51b).

81814-2G-1

51285-5 423954N

4239358

DESCRIPTION PART No. t.trG. No.

UST OF MATERIAL

' • .. • f '

242959D-A 1-G14-07

tJ• !I i

.., A

..

1 -+GF• -----~-~ .h'i"'

t------- 36" [914],------1

REQUIRED

6" [152mm]

I 23 r

[520mm]

f?\THRU~ ~CUSTOMER'S \:V ' FLANGE lj"

AI :' ' t r- L+l@_1 ~A

72"

REQUIRED

~0.625" [~15.8mm]

~1.95" [~49.5mm]

SECTION A-A

~3.875" [~98.4mm]

~5·

[~127mm]

' I ' I

--------------------------. &.

t---------404 [1M9-] I

1--------m r•J2-J I

.,.

327 [1286-] a..EARENCE FOR

BASKET RDIOVAL

\ f ' I I { ) \

OUTLET~

~l 1-1/2~ 1501b ANSI FLANGES

I >;:;;.,.. ... .-;;..""' 394[15j-J '

J.40[13f]

241 r•l1

83 r>i-J

!

f I ' I IJ I ' ' ' " ' • f • ' •

STRAINER BASKET CLEANING INSTRUCTlONS

1. DE-ENERGIZE CHLOROPAC SYSTEI.t

2. CLOSE ISOLATION VALVES TO STRAINER OR CHLOROPAC SYSTEM.

3. DRAIN STRAINER BY REMOVING 10 [3/8"] PLUG.

4. REMOVE GASKElED STRAINER CAP BY TURNING HANDL£5 (lOCAlED ON ITD.I 1) COONTER-CLOCKWISE.

S. RDAOVE BASKET (ITEM 4).

6. CLEAN BASKET AND INSPECT SCREEN FOR WEAR.

7. CHECK STRAINER BODY FOR (ITEM 3) FOR DEBRIS &: 'lt'EAR.

8. REPLACE CLEANED BASKET.

9. TIGHTEN STRAINER CAP BY HAND UNTIL SEOJRE.

10. RUN SEAWATER THROUGH CHLOROPAC S"'"SlEM fOR 10 t.fiNUTES AND INSPECT STRAINER FOR LEAKS.

11. ENERGIZE CHLOROPAC SYSTEM TO RESUME NORMAL OPERATION.

12. ASSEtro4BUED WEIGHT IS 7.5kg (16.51bJ

' ' !\! Jl ' f ' f ' r " ~ ' t '

~I i ~I

~

CD PRESSURE PORT 1 I 4"NPT \ [ ] \ PORTS@ & @ARE EXHAUST PORTS

...-rl -'---L1

246 [9ft "]

NOTES:

1. CONNECT PRESS URE TO PORT CD. 2. EXHAUST PORTS CAN BE LEFT OPEN.

120VAC ·~~ GRN II GND

SOLENOID VALVE

I I 120 VAC I

INPUT

WIRING DIAGRAM

\ \ \

-- -'-'./

~ ct I I

I I

,-----IT.:J_ l -CTT n ~

I

~-

- 1- ~INLET

L165 [';\1

LJ

KACE BALL VALVE, HASTELLOY C BODY WEIGHT: 2.2kg [27 .81b]

A I IN Ill AL RELEASE REV DESCRPmN

8-7-09 I JLM I I CVP DWN CHKD ~PVC

1:::!:::-::::, ~

127 [5"]

l BY

MARAD

A. B.S.

U.S.C.G.

OWNERS

¢16 [¢~"]

¢99 [¢3~"]

APPROVALS

"""'" UR. NO. I DJ.1E

HULL NO

INSTALLATIONS 1--------i--------+-__,j

I I"'" 111TI.E INSTALLATION DRAIMNG ~ 8-7-09 M.G.P.S. (ANllFOUUNG DEVICE)

'""-DATE BALL VALVE W/ACT. 1-1/2" FLGD. HAST.C P/N GBA04160

DATE 8-7-09

CUENT MSC

"""'"" 2429590-A3-G14-1 0 REV

A


SECTION VII

SPARE PARTS LIST - 4 lb/h CHLOROPAC® SYSTEM

TABLE VII- 1 4 lb/h POWER SUPPLY

TABLE VII- 2 1 lb/h CHLOROPACI8JMK1M GENERATOR CELL

TABLE VII- 3 4 lb/h CHLOROPACIBJ MK 1M GENERA TOR

TABLE VII- 4 MODEL 8035 FLOW TRANSMITTER

PAGE 1 OF 5


ITEM

4

5

6

7

12

16

17

18

55

56

57

59

60

SODIUM HYPOCHLORITE GENERATING SYSTEM

4 lb/h CHLOROPAC® POWER SUPPLY

Part Number: 50682-004SW-02/-04

SPARE PARTS LIST

QUANTITY PART DESCRIPTION PART AVAILABILITY NUMBER

1 Current Sensor, 500 A DC 81481-5 STOCK

1 Voltage Transformer, 14 kHz, 13.5 81491 STOCK kW

1 INDUCTOR, 28 kHz, 450 A DC 81546 STOCK

1 IGBT Module, 150 A AC 81589 STOCK

1 Meter, 2" Square, 0 to 500 A DC 82410-4 STOCK Scale

1 IGBT Driver Board Assembly 82162 STOCK

1 PWM Board Assembly 82159 STOCK

1 CHLORO Board Assembly 82389 STOCK

1 IGBT Snubber Board Assembly, 81655-1 STOCK Right

1 IGBT Snubber Board Assembly, 81655-2 STOCK Left

1 Fuse, AC Input, 30 A AC 74666-12 STOCK

1 Meter, 2" Square, 0 to 40 V DC 82410-9 STOCK Scale

1 Fuse Rectifier, 250 A DC 55658-11 STOCK

TABLE 7-1

PAGE 2 OF 5


SODIUM HYPOCHLORITE GENERATING SYSTEM

1/2 lb/h CHLOROPAC® MK 1 M GENERATOR CELL

Part Number: 50669-001-M

SPARE PARTS LIST

COMPLETE CELL SILVERLABE SILVER LABEL SILVER LABEL 43" LONG 43" LONG 43" LONG

Generating Cell 50669-002-M 1 50669-002-M2 50669-002-M3 Complete

Item Com12onents Standard 1/2 lb/h Cell 1. Outer Shell, Cathode (-) 51320-012 51320-012 51320-002

(8" LX 2.875" 0.0.)

2. Outer Shell, Anode (+) 73363-005 73363-005 73363-005

(8# LX 2.87" 0.0.)

3. Inner Shell, Electrode 73364-002 73364-002 73364-002

4. Plain Union 77152-001 77152-001 77152-001

5. Union, Tapped, Pinned 77152-003 77152-003

6. Union, Pinned 77152-004 77152-004

7. "0"- Ring 50632-002 50632-002 50632-002

9. Nut, Union 77153 77153 77153

10. Cone, Spacer 77159 77159 77159

11. Stub End Split 77154-001 77154-001 77154-001

12. Cement, CPVC Solvent 50660-002 50660-002 50660-002

TABLE 7-2

PAGE 3 OF 5

~'·

II"

fi>r

.. 11¥.-

IIIII

IIJ!i!

iv--

p

'"'

•

• IIIII-

->!J;.

Ill'

lit

.. It ., • ... Ill!'

""'' u,

""''' ...

""''

"" l<c


SODIUM HYPOCHLORITE GENERATING SYSTEM 4 lb/h CHLOROPAC® MK 1M GENERA TOR

Part Number: 51 084-M SPARE PARTS LIST

ITEM QUANTITY PART DESCRIPTION PART AVAILABILITY NUMBER

2 1 Generating Cell 5066g-002-M3 STOCK 3 1 Generating Cell 5066g-002-M2 STOCK 5 4 Nut, Union 77153 STOCK 7 2 Spacer split, 2- 118" OD 80010 STOCK 8 2 Inlet I Outlet Flange 77155-001 STOCK g 1 Return Bend Assembly 807g2 STOCK 12 AIR CPVC Cement 50660-002 STOCK 13 1 Bus Bar, Cu 76068 STOCK 14 2 Terminal Block 50731-001 STOCK 15 1 Terminal Block End 50731-002 2 weeks 17 1 Cover and Gasket 50g55 2 weeks 20 1 Leak Detector Assembly 51077 STOCK 23 1 Gasket NPRN access 36882 STOCK

plate 24 1 Leak Detector Clamp X2202 STOCK 31 AIR Pipe Dope Ribbon 51120-002 STOCK 35 2 Reducer, %" x %" 54g27-004 STOCK 43 2 Bolt Eye 37g47 STOCK 45 1 Nipple,%", short 51872-001 STOCK 46 1 Valve, Angle, %" FPT 51581 STOCK 47 6 "U" Bolt, 318"- 16 x 5 -112" 51178-001 STOCK 65 1 Elbow I w goo (CPVC) 52758-001 STOCK 66 2 Spanner Wrench 56337 STOCK A1 1 Pressure Switch 52558-005 2 weeks A2 AIR 114" Poly, Tubing 51283-002 STOCK A3 1 Male Connector, Tx114" 51863-001 STOCK A4 1 Tee, 1/4" T 51387-002 STOCK A5 1 Flow Meter Assembly 51520-003 STOCK A6 1 Connector, goo , 318" 52069-001 STOCK A? 1 Flow Meter Assembly 51520-003 STOCK (A*= represents Additional material, not listed on the Generator Assembly drawing)

TABLE 7-3

PAGE40F5


SODIUM HYPOCHLORITE GENERATING SYSTEM MODEL 8035 FLOW TRANSMITTER, 1-1/2 INCH UNION WITH CABLE PLUG

Part Number: 81814-5 SPARE PARTS LIST

ITEM PART DESCRIPTION PART NUMBER (External)

1. 1 - 1 '2" Union with paddle wheel 81814-20-6

(Internal 11. Cable Plug 81814-21-1 12. Cable Plug, USA Version 81814-21-2 13. Sensor Housing, Plug 81814-21-3 14. Instruction Manual 81814-21-4 15. Paddle Wheel "0" - Ring, FPM 81814-21-5 16. Paddle Wheel "0"- ring, EPDM 81814-21-6 17. Wheel "0" Ring FPM Axis & Bearing 81814-21-7

TABLE 7-4

...

!IIIII'

PAGE 5 OF 5

TERMINAL BLOCK

FbQW SETliNGS 18GA·

N0Rtr1~25 SHL'D LOW 20

IMRING DIAGRAM WIRING FROM POWER SUPPLY TO BE FURNISHED BY INSTAu.AllON AC11\!1TY

LEAK BLK DETECTOR

212 MCM CABLE

~~. ~-

CENTER OF GRA\!1TV VEIGHT-270 LBS.

1[1\2T(JB) ou

I 6(7\8T{175)

l1[1\2T{JS) I

I 6[1\2!(165)

I 2"(51)J

26 24 22 20 18

"""" 14 12 10

• •

PRESSURE DROP 25 GPM-8.6 PSI

1234567 S!tO

pg (OPERATING AT FUll OU1PUT)

NOTES: 1. TEST UNIT IN ACCORDANCE TO SP-50933. 2. TORQUE ELECTRICAL CONNECllONS TO 20 FT LB. 3. DRA.IN VALVE LOCATED A.T INLET.

VENT/SAMPL.£ VALVE LOCATED AT OUll.fT. 4. SPANNER YIRENCHES ITEM 66 TO BE SUITABLY

PACKAGED .t SHIPPED INSIDE Of UNIT.

(,~~- I -r---------------<i~ I

~ ' .. • '

HQlfS;,. 1. STAUP COldPONENT IDENTIFlCATION AS SHOWN PER SP327J7. 2. WIRE IN ACCORDANCE WITH DRAWING A1-82-420. 3. INSPECT AND TEST PER SP82389. 4. INSTALL J.IMPERS ON TERMINAL BLOCK 18101 & TB102 AS SHOv.N ON OWG. A1-82420. 5. APPLY A THIN FlUA OF' lHERUAL GREASE, ITEM-51, TO MOUNTING SURFACE OF" ITEI.I-7.

,--------------, 1~1

I I I I I

I I I I I I I I I I I I L __

1.:. • ._.. • I ••••• •0

I I

I I I I I I I

I ®I

___ lf: ___ j

g g g ()·@@() 1'81 It\ R2 SWI

"' r--, I@ I L _ _j

1. ~~"/--.-·-~''Fi;]-...!r c===~"iAPI'I.AR-IN..;~Ng0~~~ ~~E ------------------------~--~I~NTIIE~Rlli!OHRLYV~IE~W---------------------------------

SIEe...1 -~-I'Ud[ ~

P~l=_::=ll II v~ L AIR FLOW PC!

~~ I• [~:H~.~~ ~ (l •

PC2

~ •

~

~

' • f • I ' ' I f • !I' ~ "' 11 If !I ' 'I ~ • t t 1 I

I " , /' ,,,~ r--~~1 r---''"~ PORT CONNECTION

1RUE UNION CONNECTION 'MlH SOLVENT /FUSION SPIGOT

5l6 )TVPICAL

EI..CAT P/lol I now lR.t.NSr.IITTER ASSEWBLY 1(1\2T W/PIPE AND FITTINGS

f803S FLOW TRANSMITTER. (1\2T UNION W/CABI..E PlUG

1511514-2 1111035 FLOW TRANSMITTER, (3\4T UNION W/CA8l.E PLUG

81814-J 18035 FlOW lli:ANSt.tiTTER, 1~ UNICH W/CABI..E. PLUG

81814-4 lf8035 FlOW TRANSMITTER. 1{1\4T UNION W/CABLE PLUG

81814-5 18035 FLOW TRANSUITTER, 1[1\2T UNION W/CABL.E PLUG

81814-e 18035 FLOW TRANSMITTER. 2" '-"'iON W/CABLE PLUG

18035 FlOW TRANSMITTER, 2[1\2T SAOOL£ W/CA&tL PLUG

18035 FlOW TRANSWITTER, ~ SADDLE W/CABLE PLUG

81814-9 lf5035 FLOW TRANSMITTER, 4" SADDLE W/CABL.E PLUG

81814-10 18035 FLOW TRANSWITTER, DN 15 UNION W/CMAE. PWG

81814-11 lfi8035 FLOW TRANSMITTER. DN 20 IMION W/CABLE PUJG

81814-12 f803S FLOW TRANSMITTER. ON 25 UNION W/CABLE PLUG

81814-13 18035 FLOW TRANSWITTER, ON 32 UNION W/CABLE PLUG

81814-14 f803S FLOW TRANSt.IITTER, ON 40 UNION W/CABLE PWQ

81814-15 f803S FLOW TRANSWITTER, DN :50 UNION W/CABtE. PLUG

81814-111 FlOW TRANSMITlER ASSEl.la...Y 1" W/F'IPE AND FlTnNG$

81814-17 FLOW 'TRANSWITIER ASSDEILY (1\2T W/PIPE Nl> F1TI1NCS

El.CA.T Pftl EXlERNAL SPARE PAATS UST

TRANSMITTER 120VAC

[1\2T UNON W/F'ADOL..E 'MIEEL

[J\4T UNION W/PADDI..£ 'M'£II...

31814-20-4 1" UNION W/PAOOLE 'M£El

81814-2~5 1[1\4T UNION W/PADDL£ 'MiEB..

81814-20-fl 1[1\2T UNJCil W!PADDLE MlE£1.

81814-20-7 2" UNION W/PAODLE 'MiEEL

81814-2G-8 2(1\2T SA.OOU:

81814-2D-0 S' SADDLE

81814-20-10 4• SADDLE

81814-20-11 ON 15 UNION W/PADOL.E M£El.

ON 20 UNIOM W/PADDLE 'M-IEEL

ON 25 UNION W/PAOOLE WIHEEl

81814-20-14 ON 32 UNION W/PADOLE: 'M-IEEl.

81814-2D-15 ON 40 UNIOM W/PADDLE 'MiEil.

81814-20-18 ON 50 UNIOM W/PADOLE: 'M-I£El..

81814-20-17 TRANSMITTER 24\oOC

W:AT P/N I IN'!ERNAl SPARE PARTS UST

81814-21-1 : CABLE PLUG

CABlE PLUG-USA \USION

SEN~ HOUSING, PLUG co.IN

81814-21-4 INSlRUCllON MANUAL

(•) 81814-21 5 PADOLE WI-£D. "0"-RING FPitl

81814-21-11 PADOLE wt£D. •o• RING EPWO

81814-21-7 w-IEEL "0" RING FPiol AXIS &: BEARING

FLOW TRANSMITTER ASSEIABL Y DETAilS

UST OF lr.IATERIAI... Pjtoi"S

ITEM 11 I llEiol 12 lllEiol fJ l•lEiol,. liTEM fS I11Eiol 16

81814-2D-1 1::::=: 15125S-5151278-81S8798-31!5086D-21 NOTE 12

81814-20-3

181814-20-4

81814-20-8

81814-20-11

11814-20-14

81814-20-4 51258-3 51278-11 567H-3 5011110-2 NOTE f2 8181+-2D-1 81814-20-2 51258-1 51276 4 567H 3 50&6D-2 NOTE 12

lr.IFR P/N

423051K

'""" "'""'

'"""" 423942J

'"""" t.lnt P/N

4242052

4242065

42113400

41~76()1(

MQIE;_

1) (•) ASTERISK INDICATES WHICH CABlE PWG PART NO.

2)

IS BEING USED FOR DASH NO'S -1 lHRU -15.

CONSTRUCT AS SHO'MII IN lHE •n.ow TRANSMITTER ASSEWBlY DETAilS".

1 I REVISED NAioiEPI.ATE

2JOVAC JL ____ ...J I {_~-. ___ j I I

11~AC _jl ______ J

1N1£RNAI..

"""" ,..,.._y

OPEN: NORir.IAL FLOW OPEN: LOW FLOW a..OSE: LOW FLOW a..OSE: NORWAL. FLOW


IFsrfsw~~~:~~~E~

1D--1Hlll.t.M I DP

ON UN (INCH) VARIABLE DIMS {INCH)

PIPE SIZE l U H l4

15 ( 1 2 5.04 3.55 4.81 33.55

20 ( 3 • 5.67 3.94 4.69 33.94

2s <n 6.30 4.33 4.73 34.33

32 (1[1\4T) 6.62 4.33 4.85 34.33

40 1 1 2 7.41 4.73 5.00 34.73 so (2) 8.35 5.12 5.28 35.12


I. ~'i: -:-:~·

YElL BURKERT FLUD CONTROL SYSTEMS

JilimJEil;_

BURKERT CONTRC..."TlC CORP. IR....,NE CA 92614 PHONE 223-3100

SEE TABL£

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SECTION VIII

SYSTEM CONTROL PANEL

MODEL: ECP03000-001

8.1 SYSTEM DESCRIPTION AND THEORY OPERATION

8.1.1 System Control Panel Overview

The System Control Panel (SCP) controls the chlorine concentration at each ship's discharge by comparing the interpreted value of chlorine concentration with a desired adjustable set point value of chlorine concentration set close to, but not to exceed 0.1 ppm. The PSC incrementally raise or lower electrical DC current supplied to the EGG's, in order to regulate chlorine concentration at the ship's discharges.

The amount of free chlorine in the seawater leaving the ship's discharge is controlled by the power supply controller. The ORP level at the system discharge is monitored by the ORP Analyzer and then transmitted as a signal to the control panel. The control panel interprets the ORP signal from the discharge and the system poise BFA to estimate the chlorine concentration at the discharge. The control panel controls the level of chlorine at the discharge by regulating the level of electric current to the EGG's, which is directly proportional to the amount of sodium hypochlorite being generated and injected into the system.

The controller controls the output of the power supply using the flow feedback from the operating pumps and ORP (Oxidation Reduction Potential) Probe. The power supply is controlled from a SCP (System Control Panel) in Automatic Mode only. The SCP contains an Automation Direct's Direct Logic 06 Series PLC that is programmed for and is dedicated to the control of the chlorination unit. It also consists of analog & digital input/output cards. The SCP supplies 24Vdc to the flow meter, Rosemount Analyzer, Red lion HMI (Human Machine Interface), DLC (Dual Loop Controller). All of the indications to operate the power supply in automatic and manual modes are available locally at the SCP. All system alarms are available locally at the SCP. The following indication is available from the SCP.

1. AC Power ON

Also, below fault indications are displayed on Alarm Screen of the HMI.

2. Generator Low Flow 3. Generator Leak 4. PS common Failure

The process is continuously monitored by the flow meter. The PLC utilizes the various monitors to protect the system from operating in unfavorable conditions.

PAGE 1 OF 18

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Any system abnormalities I out of specification fault conditions detected cause an automatic safe shutdown of the system.

8.1.2 Theory of Operation

System should always run in automatic mode with auto/manual switch located on power supply in auto position.

Initial Energizing is as follows:

a. Input Circuit breakers are "OFF" on Power Supply and System Control Panel.

b. Make sure the push/pull switch on E-Stop Panel is in "Pull" position.

c. Based on High or low sea chest control valves (MOV-1 thru 4), Dispersal Pipe control valves (ABV-1 or 2) will be open respectively.

d. Flow to generator is 20-25 GPM

Note: Make sure the pumps are running before the power to the unit is turned on.

e. Automatic Manual Switch is on Automatic Position located on Power Supply.

f. Manual Potentiometer located on Power Supply is fully turned to counter clockwise position.

g. Input Circuit breakers are "ON" on Power Supply and System Control Panel.

h. On Power Supply Green light is illuminated for "Normal Flow ON". If the red light is illuminated on power supply ("Low Flow" alarm displayed on HMI of SCP), inadequate flow of water is in the generator or a water leak is inside the case.

i. All or at least one pump ON. Based on the pump input power supply will output current to produce required sodium hypochlorite initially.

j. Within few minutes, output of power supply will be adjusted based on ORP feedback signal to maintain overboard discharge level to 0.1 ppm.

The power to the system control panel must be turned on before the power to the Power supply. A PLC located on the system control panel permits the unit to be set to maintain an appropriate level of Hypochlorite output based on pump and ORP feedback inputs. A manual setting (constant current) is also provided as a backup from SCP. At this time, "AC Power ON" lamp on CONTROLLER should be illuminated on power supply. Once there is efficient flow through generator,

PAGE 2 OF 18


Normal flow indicator should be on. If there is any problem with power supply PS-1, Common Fault indicator will be illuminated and "PS-1 Failure" will be displayed on System Control Panel.

8.1.2.1

The System Control Panel has two modes of operation: Auto and Manual. In both of these modes, the SCP MOV's automatically controls the diffuser MOV's based on signals received from the associated sea chest MOV's.

System Function - Auto Mode

In Auto operation, the chlorine output of the system is controlled by the total flow through various pumps and if the chlorine output is not sufficient enough, then the chlorine output is controlled by the feedback signal from the ORP probe. Automatic mode is the normal operating mode of the CHLOROPAC® system.

Note: This mode of operation is only possible on systems with ORP installed.

8.1.2.2 System Function - Manual Mode

Manual operation of the CHLOROPAC® system is only necessary for maintenance, troubleshooting, or if a failure of the automatic control system occurs.

In Manual operation, the chlorine output is controlled by the value of power supply output current that the operator enters into the red lion controller. In Manual operation, the chlorine output is controlled by the value of power supply output current that the operator enters into the Red Lion Controller. A signal from the Red Lion controller adjusts the output current just as it does during auto mode. The controller adjusts this signal until the measured output current matches the current set-point chosen by the operator. The current feedback from the power supply provides stable current output and, given stable water conditions (salinity and flow), provides stable chlorine output.

8.1.3 Specifications

Input 120 VAC ± 5V. 60Hz. Single- Phase Voltage:

Output: 0-20mA or 4-20mA

Construction: Welded steel drip-proof enclosure finished in MUNSEL 7.5 BG 7/2 Blue/Green.

Enclosure is 28.5" H (508mm) x 22.5"W (508mm) x9"D (230 mm) overall, Dimensions: with 4 mounting holes for bulkhead mounting on 21 9/16"H (548 mm) x

18 Yz" W (470 mm) centers.

Weight: 65 lbs. (29.5kg)

PAGE30F18


8.1.4 Controls and Indicators

8.1.4.1 AC Power on Indicator

The power on indicator consists of white light mounted in the front panel of the control panel. The light is illuminated whenever 120Vac power is available from the ship and DS-1 is closed.

8.1.4.2 General Failure Alarm Indicator

The warning indicator consists of a red light mounted in the front panel of the control panel. The light is illuminated whenever an alarm condition is detected by Red Lion controller through PLC located on system control panel.

8.1.5 Unit Components

8.1.5.1 Power Input and DS-1 Disconnect Switch

The System Control Panel receives 120Vac, 1<t>, 60Hz (supplied by client) power through Main disconnect switch DS-1. This power is converted into 24Vdc power through the provided power supply.

8.1.5.2 DLC (Dual Loop Controller)

Dual Loop Controller is powered using 24Vdc. DLC is used to convert the input signal 0-4Vdc from power supply current sensor into 0-20mA signal for the PLC.

8.1.5.3 PLC (Programmable Logic Controller)

PLC is powered using 24Vdc supplied from the internal power source. Based on pump flow inputs, PLC compares pump flows to 0-20mA signal. If the flow is 100%, PLC outputs 20mA. This mA signal is transferred to the Power supply, asking it to output 100% load.

8.1.5.4 ORP Analyzer

ORP Analyzer is powered using 24Vdc supplied from the internal power source. Based on ORP Probe reading, ORP analyzer converts the mA signal into BFA Discharge Chloride level (ppm) value. The ORP (Oxidation Reduction Potential) measures the amount of active chlorine remaining in the discharge water of the air conditioning plant seawater cooling system. This is performed by drawing a small amount of water from the overboard discharge. The ORP produces a voltage proportional to the amount of active chlorine in the sample. The ORP probe measure the oxidation-reduction potential of the water relative to a standard electrochemical cell. This voltage is measured and interpreted by an electronic ORP analyzer located in the SCP. The analyzer displays the residual chlorine level (ORP mV reading) on it's built in screen and outputs a voltage signal to the PLC's Analog in/out module. The PLC module digitizes the voltage signal through an AID converter and provides the digital data to the Red Lion

PAGE 4 OF 18


controller by means of RS-232 port. The concentration data provided by the analyzer is used by the PLC to adjust it output current.

8.1.5.5 Red Lion Controller Display

The Red Lion controller, located on the front panel of the System Control Panel, provides a touch-screen interface for the operator. Using the touch-screen and the menu buttons located on the front of the controller, the user can control the current output of the power supply in automatic mode. The Red Lion controller display screen provides various display screens that provide system operating information to the operator. Refer to figures x though y for illustrations of each of these screens.

8.1.5.5.1 Menu Screen

The Menu screen, shown in Figure 1, can be accessed at any time during operation by pressing the MENU button on the front panel of the Red Lion Controller. This screen permits the operator to access the several other screens by pressing buttons on the touch-screen display. It also displays the current date and time at the top of the screen.

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Figure 1: Menu Screen

8.1.5.5.2 Alarm Screen

By pressing Alarms button on the Menu Screen, the operator can view Alarm Screen shown in Figure 2, where all alarms are caused by any fault conditions. These alarms are also displayed on bottom of each screen to indicate existing alarms. If there are no existing alarm conditions, operator will read "No Active Alarms" on each screen. Once the alarm condition is met, operator can accept the alarms and exit the screen to go to Menu Screen.

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Figure 2: Alarm Screen

8.1.5.5.3 Mode Screen

By pressing the Mode button on the menu screen, the operator can call up the mode screen (As shown in Figure 3). This screen allows the operator see which mode the system is currently operating in and what is the output of the power supply. Operator can change the modes as necessary. Two mode indicator buttons are located on the right side of the screen. The one labeled: Auto allows the operator to choose Bio Fouling Feedback Control of the system as well as the pumps flow to control the system. The one labeled: Manual mode, a operator can enter the desired output current by pressing the SET POINT icon at the top of this screen. This will cause a numeric keypad to appear, allowing operator to enter the desired value.

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Figure 3: Mode Screen

8.1.5.5.4 System Screen

By pressing the System button on the Menu Screen, the operator can call up the system screen (As shown in Figure 4). This screen provides important system status information to the operator. In the upper left corner of the screen, the output current and the mode of the system are shown along with generator status (Leak, Low Flow or Ready). On the right side of the screen, high/low sea chest is displayed. All of the pumps, which are connected to different sea chests, are shown on the system screen. If any of the pumps are turned on and there is a water flow through it, the blue line will turn green and respective sea chest will be green as well, to indicate there is flow through valves.

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Figure 4: System Screen

8.1.5.5.5 BFA parameter Screen

By pressing the BFA Parameters button on the Menu screen, the operator can call up the BFA Parameter's screen (As shown in Figure 5). This screen displays the BFA parameters and allows the operator to make changes. The Discharge Set Point reading displays the current set point for residual chlorine. This is the amount of residual chlorine that PSC will try to force the system to deliver when operating in Automatic BFA Mode. The default setting is 0.1 parts per million (ppm).

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Figure 5: BFA Parameter Screen

8.1.5.5.6 Set Points Screen

By Pressing the Set Points button on the Menu screen, the operator can call up the set point's screen (As shown in Figure 6). The gain reading displays the gain factor applied to the chlorine feedback signal. The higher the number is set, the faster the PSC will try to drive the chlorine output to match the set-point. However, if the gain is set too high, the system will be unstable and the output will swing up and down. Both the chlorine set point and the gain are adjusted by touching the respective box and entering the desired value on the numeric keypad that appears.

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8.2

Figure 6: Set Point Screen

INSTALLATION

Prior to operation, check all wiring to insure positive and negative leads are correctly connected to their respective terminals on the generator and that the control wires are connected to their proper terminals. Also, make sure all pump inputs, flow meter input and leak inputs are properly connected to system control panel.

8.2.1 Location

The controller should be located as near to the Power Supply as possible, and in a location protected from the weather. The following factors should be considered in selecting a suitable mounting place:

1. The air temperature should not exceed 50° C (122° F)

2. The mounting location should be reasonably accessible with adequate clearance for door opening in front of the unit. Minimum of 3' clearance is recommended. Also, unit should be protected from direct water spray or rising stream.

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8.2.2 Wiring

The Table 5-3 shows the number and correct wire sizes to be used in the installation. The input power cables are connected to DS-305 terminals A, B, C and the control wires from the power supply, flow meter and pumps are connected to TB-1. The leak detector wires are connected to Intrinsic Safe relay ISR-537. The interconnecting wiring is accomplished as shown in Table 5.1 below:

SCP FLOW CLIENT MIN WIRE DESCRIPTION TERMINALS GENERATOR METER INPUTS SIZE

ISR 537-1* COM 18AWG Leak detector

ISR 537-3* NO 18AWG

P24 9 18AWG Normal Flow

428 10 18AWG

304 H L 12AWG 120VAC

304 N N 12AWG

301H L 14AWG

301N N 14AWG Input Power Supplied by Client

301G G 14AWG

356 Pump 1 Com 18AWG Fire/Sprinkler Pump 1

P24 Pump 1 NO 18AWG FM-PMP-001





362 Pump4 Com 18AWG Fire/Sprinkler Pump 4

P24 Pump4 NO 18AWG FM-PMP-004

366 Pump 5 Com 18AWG Distilled Feed Pump 1

P24 Pump 5 NO 18AWG

368 Pump 6 Com 18AWG Distilled Feed Pump 2

P24 Pump 6 NO 18AWG

370 Pump 7 Com 18AWG Bilge/Ballast Pump 1

P24 Pump 7 NO 18AWG

372 Pump 8 Com 18AWG Bilge/Ballast Pump 2

P24 Pump 8 NO 18AWG

381 Pump 9 Com 18AWG Central Seawater Cooling

P24 Pump 9 NO 18AWG Pump 1





391 MOV-1 NO 18AWG

P24 MOV-1 COM 18AWG Sea chest Control Valve MOV-1

393 MOV-1 NC 18AWG

395 MOV-2 NO 18AWG Sea chest Control Valve

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P24 MOV-2 COM 18AWG MOV-2

397 MOV-2 NC 18AWG 442 MOV-3 NO 18AWG

P24 MOV-3 COM 18AWG Sea chest Control Valve 444 MOV-3 NC 18AWG MOV-3 446 MOV-4 NO 18AWG P24 MOV-4COM 18AWG Sea chest Control Valve 448 MOV-4 NC 18AWG MOV-4 410 SV-1 NC 18AWG P24 SV-1 COM 18AWG Sea chest Control Valve SV-1 412 SV-1 NO 18AWG

434 SV-3 NC 18AWG P24 SV-3 COM 18AWG 436 SV-3 NO 18AWG Sea chest Control Valve SV-3

534C COM 18AWG System Alarm Common System Alarm "ON" Open

534A NO 18AWG Contact System Alarm "ON" Close Contact

5348 NC 18AWG

Table 5-1: Interconnection Wiring Table

Note: *ISR 537-1 The terminal # 1 is located in the rela ISR-537 *ISR 537-3 The terminal # 3 is located in the rela ISR-537

Interconnecting wiring between System control panel and power supply should be as shown below:

PS Terminals SCP Terminals Min Wire Size Description

TB102-1 TB1-466 18AWG

0-10VDC Signal from SCP

TB102-4 TB3-N24 18AWG

TB102-22 TB1-406 18AWG

PS FAILURE ALARM

TB102-24 TB3-P24 18AWG

TB101-21 TB1-455A 18AWG

0-4VDC Signal from PS Current Sensor

TB101-22 TB1-455B 18AWG

Table 5-3: Interconnection wiring for PS and SCP

In order to maintain the highest efficiency of the system, the generator and power supply should be located as close together as possible. Voltage drop between units

PAGE 13 OF 18


should be kept below one volt and cable choices should be made in accordance with the distance between units as shown in the table below.

AWG Wire Size Max. length for one volt drop at 100Amps

#2/35mm2 56 Ft./17m

#1/0 /50mm2 89 Ft./27m

#2/0 /70mm2 112 Ft./34m

#410 /90mm2 179Ft. 155m

Table 5-2

8.3TROUBLESHOOTING AND REPAIR

8.3.1 Procedures

The purpose of this section is to locate a faulty subassembly or system component in the overall system and to get the system back on like as quickly as possible and to order parts or to inform an Electrolytic repair technician of problems with the system. Generally there are no repairs possible to a subassembly or a component, and the item will be replaced. Details on replacement of components is not provided as the normal replacement procedures consist of removing and reconnecting fasteners, disconnecting and reconnecting wires, and unsoldering and soldering wires.

Data recorded should be reviewed before starting the troubleshooting tests. More than one fault may be present at the same time, so there may be a number of symptoms. After corrective maintenance is performed, the system should be checked to see if proper voltage and current levels for the given water conditions are being delivered. Refer to section 5.4.3. This will uncover any fault, which may have been masked by other faults.

8.3.1.1 Rosemount Analyzer Programming

Once the system is turned on, program Rosemount Analyzer Solu Camp II. In order to program analyzer, follow the procedure below.

1. Click on MENU. Move cursor to "PROGRAM" using up-down arrow. Press Enter.

~ Move cursor to "Outputs", and then Press Enter. ~ Move cursor to "Output Range" and press Enter. ~ Move cursor to " Output 1" , Press Enter

PAGE 14 OF 18


~ Change "Out 1 S1 Range" to 4mA ~+ 0200mV. Press Enter ~ Change "Out 1 S1 Range" to 20mA ~ +1000mV. Press Enter

2. Click on MENU. Move Cursor to "PROGRAM", Press Enter Move cursor to "Measurement", Press Enter

~ Select "ORP" for S1 Measure.

3. Click on MENU. Move Cursor to "PROGRAM", Press Enter ~ Move cursor to "Alarms", Press Enter ~ Move cursor to "Alarm Configure", Press Enter ~ Move cursor to "AL 1", Press Enter ~ AL 1 S1 is for?? Select Measurement and Press High & Enter ~ AL2 S1 is for?? Select Measurement and Press High & Enter ~ AL3 S1 is for?? Select Measurement and Press High & Exit ~ Move cursor to "Alarms", Press Enter ~ Move cursor to "Alarm Set point", Press Enter ~ AL 1 is set for High Value to +1400mV

4. Click on MENU, Move cursor to "Calibrate", and Press Enter ~ CAL SENSOR 1 is set to "Measurement"

8.3.1.2 DLC Programming

The Before Power up, be sure to change jumpers and dip switch settings accordingly. 1. Serial DIP Switch Setting: Default Switch (ON). Other switches stays in

OFF position 2. Analog DC Output:

Output 1: 0-20mA Set the jumpers to Current settings 3. Inputs:

Channel A Input: 0-4 Vdc. Set the jumpers to Voltage Settings.

To download Program: a. Click on "RLCPro" software installed on desktop. b. Go to "File" c. Open "MSC2.DLC" d. To Download, go to File -7 Download (Note: Remove RS485

connector for HMI) e. When message pop up " Ok to download document to the

device at address 247 at COM 1", Click OK. f. When prompted for "Data Transmitted Successfully", Click "OK".

(Note: Place connector back on HMI.

Note: In DLC Program, output 1 is set to 0-20mA and Channel A Input to 0-4Vdc.

PAGE 15 OF 18

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8.3.1.3 HMI Programming

Note: Make sure the latest version of Crimson Software must b.e installed in the computer prior to installation.

In order for HMI to function properly, HMI needs to be configured appropriately. To do this, follow the instructions written below:

a. Go to "File---+ Open-7 MSC 06_23_09c"

b. Select the file and click OK.

c. Move cursor to "Link" on top Menu bar.

d. Scroll down to "Send" and click OK.

e. Now Program shall be sent to HMI

f. On HMI "System" screen is shown. This shows the status of each pumps and valves.

g. Click on to "Log In" in Menu screen and window will pop up where username "operator" and password "operator" can be entered.

h. Once logged in, go to "Mode" screen from "Menu" and change Mode to "Auto" from "Manual" by pressing Mode buttons. Go back to Menu.

8.3.1.4 PLC Programming a. Power up laptop with appropriate direct soft logic installed.

Note: Use PLC Cable PN: 02-DSCBL b. The switch on the PLC should be set to "term" position. Connect the

Laptop to the PLC using the connector cable. c. Set the time and date on the PLC. d. Go to "Start" menu on computer main screen. e. Select "Direct Soft 5" and go to "Direct Soft 5- Programming". f. Click on "Direct Soft 5 Program". g. "Welcome to Direct soft 1 00" screen pops up, then click on "Run Direct

soft 100". h. Now the Direct soft PLC programming screen should be on. i. Go to "File" menu and click on "Open Project". j. Now select "MSC_6_24_09.prj" and click "Open". k. This allows the PLC program to be opened in direct soft window. I. Go to "PLC" located on top Toolbar. Click on "Connect". One screen will

pop up asking to follow the steps ahead. m. Click on "Use Disk" from the pop up screen. This will allow operator to

connect to the PLC. n. Go to "PLC" located on top toolbar. Click on "Copy Configure data from

Disk to PLC". o. Now the PLC should be downloaded free of any errors.

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8.4 TROUBLESHOOTING CHARTS

AC

WARNING Hazardous voltages are present in this equipment. Ensure all tag out procedures are in accordance with current shipboard instructions. Failure to comply with tag out procedures could result in injury to personnel, and damage to equipment.

Terminals listed in these tables are located on the piece of equipment they reference.

CAUTION

The following troubleshooting charts allow troubleshooting only to the capability level of most shipboard operators and electricians. Troubleshooting and repair beyond the symptoms and repairs listed below should only be performed by or under the direction of an Electrolytic repair technician. Schematic diagrams in this manual only support trouble-shooting to this level. Serious damage to equipment can occur if repairs beyond those covered below are attempted, without details knowledge of the system components.

TABLE: TROUBLESHOOTING CHART-SYSTEM MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

Power On Lamp does not Power to unit is secured at the Turn Power on at Breaker Panel illuminate when the circuit breaker breaker panel Replace Bulb is turned on Bulb Faulty. HMI Screen is blinking Alarm Condition Acknowledge the alarm in the

Alarm screen of the HMI. Indicator lights on Dual Loop Module not programmed correctly Refer to data sheet for probable Controllers are blinking cause

Set the jumpers to correct input/output settings. Re-Program the module.

8.4.1 Voltage Checks

The following voltage checks can be made if troubleshooting procedures do not pinpoint the malfunction. This procedure should be followed after repairing a power supply. Sequential inspection will help prevent mistakes in repairs.

a. The following voltage measurements are made with the control panel circuit disconnected. Turn of 11 OVac power and secure DS-1 is in OFF position.

Terminals Voltage Check HMI Controller +24 Vdc LED Illuminated HMI Controller -0 Vdc LED Illuminated DLC +24 Vdc

On Terminal Block TBA-3&4 DLC -0 Vdc PLC +24 Vdc

On Terminal Block PLC -0 Vdc ORP Analyzer + 24Vdc

On Terminal Block ORP Analyzer -0 Vdc

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WARNING

For taking these voltage measurements 11 OVac voltage will be present. Turning Power off and connecting voltmeter to measurement points between readings is recommended.

8.5MAINTENANCE AND SERVICE

Maintenance requirements of the control panel are reduced to keeping the enclosure clean and free of obstructions which may interfere with the cooling air flow. Periodically, the unit should be inspected for dust or dirt accumulation, loose or broken connections. The unit may be cleaned with a dusting brush and suction cleaner to remove any accumulation of dust. System Control Panel does not have any moving parts to be lubricated or adjusted.

PAGE 18 OF 18

,:;., 4, ~ i l • ' j 1: ~

1-------"tt' [564]-----

FRONT VIEW (INTERIOR)

"-... _.:::::,

r 15' [381]

,~'[149] T I CENTER Of GRAVIJY

FROIA BOTIOIA Of FRONT DOOR APPROXI.ATE 1\f:IGHT: 6~b (29kg)

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INSTALlATIONS

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A I ISSUED FOR REVIEW

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QES[GN ANQ PERfORMANCE QAIA

INPUT VOLTAGE: 120VAC ±5~/lf/60Hz ±SX INPUT kVA: 1.8 UAX

OUTPUT POIIER: 4-20mA COOSlRUCTlON: WALL OR BULKHEAD UOONTED ENQOSURE CONSTRUCTlON TO IP-23. ALARM CONTACT RATlNG: 0.6A, 125VAC

FUSE DATA: INPUT: FU-307 15A, P/N 80'116-001 FU-315 3A, P/N 54273-006 CONTROL: FU-318 lOA, P/N 54273-010

~TIJL[ INSTALl.AllON DRAWING

M.G.P.S. (ANTl-FOUUNG DEVICE) .H-011 S'r'SlEt.l CONTRa. PANEL ASSDIBLY P"" ECPOJ000-001 ijjijf""""ICIDII" USC-T-AKE ,_,_,

2429590-A1-G14-02

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LEGEND

CR CONTROL RELAY DC DISCONNECT SWITCH F'AL FLOW ALARM LOW fl FLOW INDICATOR fSL FLOW SWITCH LOW FU FUSE G-1 EL.ECTROCHLORINATOR HV HAND VALVE IS INTRINSICALLY SAFE lD PILOT UGHT LT LEAK DETECTOR f.tV t.lOTORIZED VALVE PS POWER SUPPLY SCP SYSTEU CONTROL PANEL ST STRAINER TOM TIME DRAY RELAY (ON MAKE)

UI"S 0 w ~e. 0 0

~ ~ rN1i -11 1112 ,2-,rn :u~J: ~-----::::U

1PDT, 8-PIN

APP\JCHILE""" CR-508, CR-MO, CR-~18, CR-s18, CR-520, CR-522.

NOTES: 1. FOR LOCAlJON OF DEVICES SHOWN ON THIS DRAWING

SEE CONTROL PANEL SCP EXTERIOR AND INlERIOR, DRAWING NO. ECP03000-001-A1-E56-001.

2. FOR LOCAllON AND IDENTlACATION OF AU. TERI.tiNALS SEE TERMINAL BLOCK LEGEND BELOW.

3. ALL PANEL WIRING TO BE #16 AWG, SIS TYPE INSULATED CONDUCTORS, UNLESS OTHERWISE NOTED.

4. THE CONDUCTOR COLOR CODING WITHIN PANELS SHALL BE: -GREEN: ALL GROUNDING{i.e. G);

=~:tit 1122:/t ~=H~~g: .. Wl:~Nq.;e. 309H); -BLACK: ALL 120VAC SWITCHED HOT WIRES BETWEEN THE HOT AND

THE NEUTRAL(I.e. 356, 358, ETC.) -RED: ALL 24VDC POSmvE WIRING. -BLACK: ALL 24VDC NEGATIVE WIRING. -BLUE : INlRINSICAI.l..Y SAFE WIRING

TERMINAL BLOCK LEGEND:

1$) SYSTEM CONTROL PANEL ~p· TERt.IINAL NUMBER. WHERE SHOWN, ~ OR NUWBER DESIGNATES TERMINAL BLOCK TAG NUMBER IS lB-1, ETC.

e POWER SUPPLY TERMINAL NUWBER

0 OTHER TERWINAL. TYPES AS IDENTlflED ON DRAWING.

@ GROUND BUS BAR CONNECTIONS

PANEL WIRING

WIRING BY CUSTOMER

rT7 CHASSIS GROUND

SHEET I REV. L£VELIEIEIEIEIEIE INDEX I SHEET NO.Iti213I<!ISI6

LAST PLOT: 2-26-09 09:00

II i i i I i II ~ I ~

301 120VAC, 1-PHASE, SOHL, SHIP PO~ eN ~--------------------------

302

303

304

305

311

312

313

314

315

316

---------------------------------

t>---114AWG, SIS. BLACK

f14AWG, SIS,-< v.HITE

~--------------------------~~~~--------------------------~

'")--' '")--' I I

f14AWG, SIS,-( v.HITE

~ ! : [., •• ~. ~·.l

~ -"" ~ 1 lhl09 : v.HITE

<_~> J09N

r- #16AY«;, SIS, BlACK

J09H

309H FU-315 315F

3A T.O.

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TDM-311 '!'C':'\~ ~

11)1.1311-1

UNE #450 ~• 4SO (

SET 0 10 AEC.

PS-315

i L 114AV«;, SIS, GREEN

J09N

309N

(

.-L. 317 J09H

DC ON

a ~ \9

JC9N

P24 FU-318 241/DC

318 10A T.O.

319

[r-~~ 320 l'tPICAL FOR P24)

321 •

322

A'>Gl

OIT-1

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N24

BQ~~~t=~.,-•• -~-.-9-S.-BLA-ct<--~ (T'I'PICAL FOR N24)

N2-;;. Lf16AWG, SIS. BLACK

(lYPICAL FOR N2-4) (OPERATOR INTERfACE WU..INAL)

*

323 I :::8 ~IR 324

325 ..{,.. ..{,.. P24 N24

~

AC GROUND BUS BAR

~

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SECTION IX

BIOFOULING FEEDBACK ANALYZER

MODEL: BFAOOOOO

9.1 DESCRIPTION

The BFA samples the overboard discharge from the seawater cooling system by drawing a small amount of water from the discharge piping using a small pump. The water sample is passed by an oxidation/reduction probe (ORP). The ORP produces a voltage proportional to the amount of active chlorine in the sample. This voltage is measured and interpreted by an electronic ORP analyzer in the PSC. The concentration data provided by the analyzer is used by the PSC to adjust its output current.

The BFA is used to measure the amount of active chlorine remaining in the discharge water of the seawater cooling system. The BFA does this by drawing a small amount of water from the cooling system piping near the overboard discharge. The BFA contains a pump that draws the water into the BFA and then directs it through a pipe that contains the oxidation-reduction potential (ORP) probe.

The ORP probe measures the oxidation-reduction potential of the water relative to a standard electrochemical cell. This relative voltage is measured by an ORP analyzer, which is mounted in the corresponding PSC. The analyzer displays the residual chlorine level on its built-in screen and outputs a voltage signal to an input module. The input module digitizes the voltage signal and provides the data to the Red Lion controller.

The Red Lion control decides and controls the power supply output to the ECG (Electro Chlorination Generator) so that the level of chlorine treatment can be adjusted.

The ORP probe takes under to 5 minutes to respond to changes in chlorine concentration. Due to the long lag time response of the ORP probe, the control loop should make small incremental adjustments of the power supply and ECG output delayed over periods of approximately 30 to 45 seconds.

Due to the absence of pollutants in deep blue ocean seawater, not much chlorine is consumed when protecting the ship's piping while under sail. The chlorination system at sea will regulate around its set point while minimizing consumed power and chlorine discharge.

In port most of the generated chlorine will be consumed due to pollutants and higher concentrations of biological life forms. The chlorination system in port will either 1) regulate around its set point with increased system power consumption while minimizing chlorine discharge or 2) be operating at 100% output with a drop in ORP

PAGE 1 OF 8


value at the discharge below the control set point due to heavy consumption of the generated sodium hypochlorite.

The BFA pump is energized by a dedicated 115 Vac, 1-phase circuit. The power circuit is protected by a 5A circuit breaker mounted on the front of the BFA enclosure.

9.2 SPECIFICATIONS

Input 120 VAC ±5V, 60Hz. Single- Phase Voltage:

Probe Type: Oxidation - Reduction Potential

Construction: Welded steel drip-proof enclosure finished in MUNSEL 7.5 BG 7/2 Blue/Green.

Dimensions: Enclosure is 32 7/16" H (824 mm) x 24" W (610 mm) x 13 5/16"0 (339 mm) overall, with 4 mounting holes for bulk-head mounting on 31 'l4" H (794 mm) x 18" W (457 mm) centers.

Weight: 150 lbs (68 kg)

9.3 CONTROLS AND INICATORS

The simple design of the Biofouling feedback analyzer (BFA) requires only basic controls and indicators. These are described below. Refer to drawings located at the end of this section for an illustration of the BFA controls and indicators.

9.3.1 BFA Control

The only control found on the BFA is the pump CIRCUIT BREAKER. This circuit breaker allows control over the sample pump in the BFA. It also provides protection for the pump and wiring in case of a fault. The circuit breaker is operated using the toggle switch on the front cover of the BFA enclosure.

9.3.2 BFA Indicator

The only indicator found on the BFA is the POWER ON indicator. It consists of a white light that illuminates whenever 115 Vac power is available from the ship and the circuit breaker is closed.

PAGE 2 OF 8

...

•

...


9.4 INSTALLATION

Before the equipment is installed, it should be inspected for damage that may have occurred during shipment, storage, or handling. The installation of this equipment does not require any special tools.

9.4.1 LOCATION

The BFA shall be mounted in an area that is easily accessible to operating personnel. The location should provide clearances shown in figure 8-3. The space must be dry and the air temperature shall not exceed 125 degrees Fahrenheit. When mounting the BFA, consideration must be given to the routing of inlet and outlet piping.

9.4.2 INSTALLATION PROCEDURE

II WARNING II

Probes must be kept wet at all times. Install probes last after the BFA piping has been pressurized and the sample circulation pump has been operated.

This information in this section is provided to ensure the BFA is properly installed. The BFA is bulkhead mounted on four 3/8" studs or bolts arranged on a rectangular pattern 18 inches wide by 31 1/4 inches high. The required clearances are also shown on installation drawing. Connections should be made as shown on interconnection list for 115VAC, 60Hz, 1 PH to terminal TB-1 and ORP probe wiring to TB-2.

9.5 TROUBLESHOOTING AND REPAIR

It is not the intention of this section to provide all troubleshooting procedures to affect detailed repairs to the Chlorination system.

The purpose of this section is:

;;.. To locate a faulty subassembly or system component in the overall

system;

;;.. To get the system back on line as quickly as possible;

;;.. To order proper parts; and/or

;;.. To inform a SWT repair technician of problems with the system.

PAGE 3 OF 8


Generally, there are no repairs possible to a subassembly or a component, and the item will be replaced. Details on replacement of components is not provided, as the normal replacement procedures consist of removing and reconnecting fasteners, disconnecting and reconnecting wires, and unsoldering and soldering wires.

9.5.1 Troubleshooting Charts

II WARNING II

Hazardous voltages are present in this equipment. Ensure all tag out procedures are in accordance with current shipboard instructions. Failure to comply with tag out procedures could result in injury to personnel, and damage to equipment.

II CAUTION II

The following troubleshooting charts allow troubleshooting only to the capability level of most shipboard operators and electricians. Troubleshooting and repair beyond the symptoms and repairs listed below should only be performed by or under the direction of an Electrolytic repair technician. Serious damage to equipment can occur if repairs beyond those covered below are attempted, without details knowledge of the system components.

Table 9-1. BFA Troubleshooting

Malfunction Probable Cause Corrective Action BFA pump not running Power source secured Close appropriate breaker at

supply panel.

Circuit breaker CB-1 faulty Test CB-1, Replace as necessary.

BFA pump motor faulty Test BFA pump motor, see pump manual. Repair or replace as necessary.

Rapid change in residual chlorine Loose ORP probe connections Check ORP probe wiring readings from day to day connections, repair as necessary

Damaged or faulty ORP probe Replace ORP probe

Leaking BFA piping Damaged or deteriorated flange Replace leaking gasket. gasket

PAGE 4 OF 8

' ' ~


Table 9-1. BFA Troubleshooting

Malfunction Probable Cause Corrective Action BFA pump excessively noisy Pump cavitation due to lack of Check valve alignment, inspect

waterflow piping for obstructions.

Worn motor bearings Inspect motor, see pump manual. Replace as necessary

Foreign object in impeller or Inspect pump impeller, pump impeller damaged manual. Replace as necessary.

BFA pump leaking Shaft seal worn or damaged Replace seal, see pump manual.


II WARNING II

Oxidation Reduction Probe must be kept wet at all times.

The following paragraph provides procedure for the performance of the required preventive maintenance task. The ORP probe calibration must be checked monthly against a known reference to maintain the accuracy of the control system. Typical probe life is expected to be about 6 months.

a. Configure the a·ssociated Chloropac® for manual mode in accordance with SYSTEM OPERATION- MANUAL MODE (see SCP section for details).

b. Secure the power supply to the BFA in accordance with current ship's instructions.

c. Open breaker CB-1 on the BFA.

d. Open the BFA enclosure and verify that no voltage is present on the terminals of TB-1.

e. Isolate and drain the BFA piping.

1. Close the BFA inlet and outlet isolation valves.

2. Drain the BFA into a suitable container using the sample valve.

f. Remove the ORP probe from the sample pipe assembly.

1. Remove the ORP probe wiring connector.

2. Unscrew the probe from the outlet/sample pipe assembly.

PAGE 5 OF 8


g. Inspect the sensor head for any buildup or coating. If there is any present, use a soft cloth or brush to remove the coating.

h. Prepare the sensor for calibration.

1. Reconnect the wiring to the sensor.

2. Set up two test beakers with a solution of two known millivolt solutions. It is recommended to use solutions of 220 mV and 640 mV to ensure that two points of the ORP sensor's span is checked.

3. Place the sensor in one of the test solutions and observe the reading on the controller. After approximately five minutes, the value should stabilize. If that value is within 10% of the known mV value, the probe is responding. Record the reading once the value stabilizes.

4. Rinse off the sensor in clean fresh water to remove the calibration fluid, and repeat step 3 for the second mV solution. Rinse off the sensor when complete.

5. Determine which mV solution provided the greatest difference between the controller reading and the mV solution known value. That mV solution will be used to calibrate the probe.

6. Reinsert the sensor into the selected mV solution.

I. Calibrate the sensor using the ORP control indicator on the respective PSC.

NOTE

In this procedure, text that appears on the screen of the ORP control indicator is shown in bold font.

1. Press MENU on the ORP control indicator.

2. Choose Calibrate from the menu screen and press ENTER.

NOTE

When performing this procedure on an MSW BFA, skip step 3.

3. Select the sensor being calibrated (Sensor1 or Sensor2) and press ENTER.

4. Choose Measurement on the screen labeled CaiSensorN? And press ENTER.

PAGE 6 OF 8

,.,,

• ..

-

...


5. Using the arrow keys, adjust the value in the lower-right corner of the screen to read the mV of the solution and press ENTER.

6. Press EXIT twice.

j. Reinstall the ORP sensor in the BFA.

1, Remove the sensor from the calibration solution.

2. Rinse the end of the sensor with fresh water.

3. Disconnect the wiring connector from the probe.

4. Screw the ORP probe into the outlet/sample pipe assembly using pipe thread tape on the process connector threads. Do not over-tighten.

5. Reconnect the wiring connector to the ORP probe.

6. Open the BFA inlet and outlet valves and check for leaks.

7. Close the BFA enclosure.

k. Remove tag-outs and energize the BFA.

I. Return the system to automatic operation in accordance with SCP section.

9.6.1 REPAIR OF BFA

The following procedures cover the repair and replacement of the sub-assemblies of the

BFA. II WARNING II The BFA piping is connected directly to the discharge piping of Main seawater system. There might be sufficient pressure in this piping to force water through the BFA piping even when the BFA pump is de-energized. Always close the inlet and outlet isolation valves before breaking any pipe connections in the BFA Failure to do so may result in personal injury, equipment damage, and compartment flooding.

9.6.1.1 REPLACING OXIDATION-REDUCTION POTENTIAL PROBE

Refer to installation drawing located at the end of this section.

a. Configure the associated Chloropac® system for manual operation.

b. Secure and tag out the power supply to the BFA in accordance with current ship's instructions.

PAGE 7 OF 8


c. Turn off power disconnect breaker on the BFA.

d. Open the BFA enclosure and verify that no voltage is present on the terminals of TB-1.

e. Close the BFA inlet and outlet isolation valves.

f. Drain the BFA into a suitable container using the sample valve.

g. Disconnect the screw-on wiring connector from the oxidation/reduction potential (ORP) probe.

h. Unscrew the ORP probe from the outlet/sample pipe assembly.

i. Remove the process connector from the old probe and install it on the new probe.

j. Screw the ORP probe into the outlet/sample pipe assembly using pipe thread tape on the process connector threads. Do not over-tighten.

k. Connect the screw-on wiring connector to the new ORP probe.

I. Open the BFA inlet and outlet isolation valves. Verify that there are no leaks from the pump or flanges.

m. Close the BFA enclosure.

n. Return the Chloropac® system to the required operational status.

PAGE 8 OF 8

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FIELD WIRING ...... I - BFA SIDE LT-1

11 OVAC,60HZ,1 ¢

220VAC,60HZ,2¢

339[1*1--~ 192 [7rs1-

_1 89

[~1

19119

PR-1

SIDE VIEW

om mu: INSTALLAW!! ORAWNG

~~ ~~~~P~RWK1 ............. filii!! WSC-T-AICE

.... 1-1.:1= 2~0 ls~71 2429590~Gt4-os I':' 51 EM EN S~;k'':e .... -uNIO~ NJ

(~)-Mt-'12.n

SPRING RETURN DOUBLE ACTING CCW CUBIC

SIZE CUBIC INCHES SIZE INCHES

RCI210-SR 10 RCI210-DA 5.5

RCI220-SR 11.5 RCI220-DA 10

RCI230-SR 36 RCI230-DA 20

RCI240-SR 45 RCI240-DA 39

RCIO 250-SR 115 RCIO 250-DA 62

RCIO 260-SR 142 RCIO 260-DA 122

RCIO 270-SR 478 RCIO 270-DA 292

RCIO 280-SR 593 RCIO 280-DA 584

CWCUBIC INCHES

10

11.5

36

45

115

142

478

593

Pneumatic Actuator features a modern scotch yoke mechanism for high starting and ending torques in a very compact package. The RCIO Series have adjustable travel stops in both directions. Available in both double acting and spring return in 8 sizes with torques to 38,720 in. lbs., it offers great flexibility. The spring return actuator features a spring module with the spring(s) safely contained and epoxy powder coated for maximum corrosion resistance. Our pistons are guided in two places with reinforced Teflon™ bearings which insure positive alignment and long seal life. All RCI 200 Series Actuators carry a 3-year warranty.

Body Extruded aluminum, anodized finish

Spring Housings, End Caps Cast aluminum, anodized finish

Pistons Anodized aluminum

Drive Shaft Stainless steel thru RCI 260 size, plated steel in sizes RCI 270, RCI 280

Seals Buna N

Fasteners Stainless steel thru size RCI 260 Plated Steel sizes 270 + 280 Pressure Rating 150 PSI continous

Temperature

OPERATION TIME- At 80 PSI Operating Pressure Range -20° F to +170° F

Optional Exterior Finishes Epoxy or tufram SPRING RETURN

SIZE SECONDS

RCI210-SR 0.5

RCI220-SR 0.3

RCI230-SR 0.25

RCI240-SR 1.0

RCIO 250-SR 2.5

RCIO 260-SR 2.5

RCIO 270-SR 6

RCIO 280-SR 5

DOUBLE ACTING ccw

SIZE SECONDS RCI210-DA 0.25

RCI220-DA 0.25

RCI230-DA 1.0

RCI240-DA 1.0

RCIO 250-DA 1.5

RCIO 260-DA 2

RCIO 270-DA 4

RCIO 280-DA 5

cw SECONDS

0.5

0.3

0.25

1.0

2.5

2.5

6

5

Optional Constructions Low temperature or high temperature seals, low pressure hydraulic service, water hydraulic service, fast opening/ closing speed

Operating Medium Compressed air or inert gas

Mounting Dimensions ISO 5211 standard

~ REMOTE CONTROL

"-"' Remote Control Inc. • P.O. Box 355 • North Kingstown, Rl 02852

Phone 401-294-1400 • Fax 401-294-3388 • Email [email protected] Website www.rciactuators.com

.. •

RCI 200 Series RCI 200DA DIMENSIONAL DATA

Y, DEPTH• Z

J57

DIMENSIONS (Inches)

MODEL A B c E F G H J

RCI210-DA 1.77 3.85 1.26 1.61 2.95 .63 .393 1.39

RCI220-DA 3.85 3.85 1.26 1.61 2.95 .63 .393 3.15

RCI230-DA 2.56 5.30 1.93 2.17 4.25 .98 .629 3.15

RCI240-DA 5.30 5.30 1.93 2.17 4.25 .98 .629 3.15

RCIO 250-DA 3.54 7.48 2.71 2.95 6.10 1.377 .944 3.15

RCIO 260-DA 7.48 7.48 2.71 2.95 6.10 1.377 .944 3.15

RCIO 270-DA 5.70 11.60 4.33 4.33 9.76 2.36 1.574 5.12

RCIO 280-DA 11.80 11.60 4.33 4.33 9.76 2.36 1.574 5.12

----- 1 I ~---ij---"'

--~]

K

1.39

1.18

1.18

1.18

1.15

1.18

1.18

1.18

M

NOTES

SV- MOUNTING HOLES FOR SOLENOID VALVE FOR RCI270-280

ALL DIMENSIONS ARE IN INCHES

• NOT PRESENT ON RCI250DA/ 270DA ACTUATORS

•• REMOVABLE SNAP-ON CENTERING RING, FOR USE ON ISO VALVES

N p P1

1.574 1.18 1.97

1.97

4.02 2.76

4.02 2.76

4.92 4.02

4.92 4.02

5.51

6.496 4.92

MODEL S S1 T T1 U V W X V Z WT (lbs) ISO 5211

RCI210-DA 1/4-20UNC .43 1.378 .08 .553 .74 3.1 F05 .551

RCI220-DA 1/4-20UNC .43 1.378 .08 .553 .74 4.00 F05 .551

RCI230-DA 3/8-16UNC 5/16-18 UNC .67 .55 2.17 .118 .672 1.18 8.00 F07/F10 .669

RCI240-DA 3/8-16UNC 5/16-18 UNC .67 .55 2.755 .118 .869 1.18 10.60 F07/F10 .866

RCIO 250-DA 1/2-13UNC 3/8-16 UNC .83 .67 2.75 .118 4.53 .869 1.45 20.40 F10/F12 .866

RCIO 260-DA 1/2-13UNC 3/8-16 UNC .83 .67 3.346 .118 11.81 1.066 1.45 28.00 F10/F12 1.063

RCIO 270-DA 5/8-11 UNC .98 3.94 .16 7.09 1.420 2.52 69.00 F14 1.417

RCIO 280-DA 3/4-10UNC 1/2-13 UNC 1.26 .98 5.11 .196 20.87 1.815 2.52 107.00 F16/F12 1.812

RCI 200SR DIMENSIONAL DATA

r[- -j,

o/8 ll UNC, TYr. i~~~~ ll.BI RCI2BO ~~~~ -~

I<Cl <'10-240 RCI 250~280 tl" ~ IJ) "' ~K~ •. 3!~· DP .----M~ •. 31~' UP I "' --- "' t

13 ·-.56 ~----.63 4.:3:~ 1-lCli-'JD ~ j ~*""""=i'------L IYh 3.92 RCI290 - Jt~ - 1.33 RCI280

.-f--_L__--r l/4'-NPT, .47 DP .4 / l-±b i d._J .~45

h.h9 I<U?/0 924 RCI280

DIMENSIONS (Inches)

MODEL A B c E F G H J K

RCI210-SR 1.77 5.70 1.26 1.61 2.95 .63 .393 1.39 1.39

RCI220-SR 5.91 5.91 1.26 1.61 2.95 .63 .393 3.15 1.18

RCI230-SR 2.56 7.87 1.93 2.16 4.25 .98 .629 3.15 1.18

RCI240-SR 7.70 7.70 1.93 2.16 4.25 .98 .629 3.15 1.18

RCIO 250-SR 3.54 11.22 2.72 2.95 6.10 1.377 .944 3.15 1.18

RCIO 260-SR 11.22 11.81 2.72 2.95 6.10 1.377 .944 3.15 1.18

RCIO 270-SR 5.70 20.08 4.33 4.33 9.76 2.36 1.574 5.12 1.18

RCIO 280-SR 20.08 20.87 4.33 4.33 9.76 2.36 1.574 5.12 1.18

M

NOTES

SV- MOUNTING HOLES FOR SOLENOID VALVE FOR RCI270-280

** REMOVABLE SNAP-ON CENTERING RING, FOR USE ON ISO VALVES

N p P1

1.574 1.18 1.97

1.97

4.02 2.76

4.02 2.76

4.92 4.02

4.92 4.02

5.511

6.496 4.92

MODEL S S1 T T1 U V W Y Z WT (lbs) ISO 5211

RCI210-SR 1/4-20UNC .43 1.378 .08 .553 .74 4.0 F05 .551

RCI220-SR 1/4-20UNC .43 1.378 .08 .553 .74 5.85 F05 .551

RCI230-SR 3/8-16UNC 5/16-18UNC .67 .55 2.17 .118 .672 1.18 10.40 F07/F10 .669

RCI240-SR 3/8-16UNC 5/16-18UNC .67 .55 2.755 .118 .869 1.18 15.50 F07/F10 .866

RCIO 250-SR 1/2-13UNC 3/8-16UNC .83 .67 2.755 .118 4.53 .869 1.45 26.80 F10/F12 .866

RCIO 260-SR 1/2-13UNC 3/8-16UNC .83 .67 3.346 .118 1.066 1.46 40.00 F10/F12 1.063

RCIO 270-SR 5/8-11UNC .98 3.93 .157 7.09 1.420 2.52 100.00 F14 1.417

RCIO 280-SR 3/4-10UNC 1/2-13UNC 1.26 1.00 5.12 .196 1.814 2.52 142.00 F12/F16 1.811

l!lf·

•·

RCI 200 Series OPTIONAL Ml MANUAL OVERRIDE DIMENSIONAL DATA

DIMENSIONS (Inches!

MODEL A B c D E F WT/LBS RCI 210 DAIMI* 11.4 5.7 7.1 1.77 1.5

RCI 220 DAIMI 11.4 5.7 7.1 3.85 1.5

RCI 220 SR/MI 11.4 5.7 7.1 5.70 1.5

RCI 230 DA/MI* 13.4 7.5 7.1 2.56 2.5

RCI 240 DAIMI 13.4 7.5 7.1 5.30 2.5

RCI 240 SR/MI 13.4 7.5 7.1 7.70 2.5

RCIO 250 DAIMI* 19.7 11.6 12.6 3.54 6.5

RCIO 260 DA/MI 19.7 11.6 12.6 7.48 6.5

RCIO 260 SRIMI 19.7 11.6 12.6 11.20 6.5

RCIO 270 DAIMI* 31.5 20.3 15.7 5.70 26

RCIO 280 DA/MI 31.5 20.3 23.6 11.80 26 RCIO 280 SR/MI 31.5 30.3 23.6 20.0 26

*NOTE: For models 210, 230, 250, & 270, M-1 dimension for SR actuators are the same as DA actuators.

RIM PULL FORCES (LB.) To obtain an output torque equal to an air pressure of 80 PSI on the actuator

DOUBLE ACTING SPRING RETURN

RCI210-DA 14.3 RCI210-SR 14.3

RCI220-DA 28.6 RCI220-SR 32.3

RCI230-DA 26.5 RCI230-SR 26.5

RCI240-DA 53.0 RCI240-SR 60.0

RCIO 250-DA 14.9 RCIO 250-SR 14.9

RCIO 260-DA 30.0 RCIO 260-SR 33.6

RCIO 270-DA 47.5 RCIO 270-SR 47.5

RCIO 280-DA 55.4 RCIO 280-SR 62.5

Remote Control Inc. • P.O. Box 355 • North Kingstown, Rl 02852 Phone 401-294-1400 • Fax 401-294-3388 • Email [email protected] Website www.rciactuators.com

RCI 200 Series

SPRING RETURN RCI-SR SERIES Air Stroke Counterclockwise to Open - Spring Stroke Clockwise to Close

40 PSIG AIR SUPPLY 60 PSIG AIR SUPPLY AIR STROKE SPRING STROKE AIR STROKE SPRING STROKE

Model# o• 60" 90" 90" 30" o• Model# o• 60" 90" 90" 30" o• RCI210-SR 40 PSI N/A 40 PSI N/A RCI210-SR 133 44 62 97 44 71

RCI 220-SR 168 71 88 124 62 97 RCI 220-SR 265 106 133 195 97 150

RCI 230-SR 318 124 150 248 115 177 RCI 230-SR 495 186 239 380 186 274

RCI 240-SR 637 257 319 513 239 363 RCI240-SR 982 389 495 788 363 558

RCIO 250-SR 1062 380 487 761 363 549 RCIO 250-SR 1637 593 752 1195 558 850

RCIO 260-SR 2124 805 1018 1549 761 1150 RCIO 260-SR 3274 1239 1593 2389 1195 1770

RCIO 265-SR 2938 1142 1545 2490 1224 1691 RCIO 265-SR 4298 1672 2263 3798 1878 2619

RCIO 270-SR 4248 1681 2035 3186 1549 2301 RCIO 270-SR 6649 2566 3097 4956 2354 3628

RCIO 280-SR 8496 3363 4248 6549 3186 4779 RCIO 280-SR 13098 5221 6549 10178 4956 7434

80 PSIG AIR SUPPLY 100 PSIG AIR SUPPLY AIR STROKE SPRING STROKE AIR STROKE SPRING STROKE

Model# o• 60" 90" 90" 30" o• Model# o• 60" 90" 90" 30° o• RCI 210-SR 175 62 88 135 62 95 RCI 210-SR 220 80 110 170 80 125

RCI 220-SR 350 140 175 265 130 200 RCI 220-SR 440 175 220 335 170 265

RCI 230-SR 665 255 320 515 250 370 RCI 230-SR 830 310 400 635 309 460

RCI 240-SR 1330 530 665 1060 495 750 RCI 240-SR 1665 665 840 1330 620 930

RCIO 250-SR 2210 795 1020 1590 750 1150 RCIO 250-SR 2745 975 1240 1990 930 1415

RCIO 260-SR 4420 1680 2120 3270 1590 2390 RCIO 260-SR 5530 2125 2655 4070 1990 3010

RCIO 265-SR 5734 2231 3020 5062 2502 3489 RCIO 265-SR 7149 2782 3767 6337 3135 4375

RCIO 270-SR 8850 3450 4250 6720 3190 4870 RCIO 270-SR 11154 4290 5310 8410 3980 6105 -RCIO 280-SR 17700 7030 8850 13720 6640 10000 RCIO 280-SR 22125 8850 11060 17170 8320 12480

{C~::: 11\/VJ rJ!:t I 1'\M {C~:! 11\/VJ AIR START AIR END SPRING START SPRING END

DOUBLE ACTING RCI-DA SERIES Clockwise to Close

40 PSIG AIR SUPPLY

Model# o• 50"

RCI 210-DA 150 70

RCI 220-DA 310 140

RCI 230-DA 575 275

RCI 240-DA 1170 560

RCIO 250-DA 1815 860

RCIO 260-DA 3715 1770

RCIO 265-DA 5257 2474

RCIO 270-DA 7520 3630

RCIO 280-DA 15490 7300

80 PSIG AIR SUPPLY

Model# o• 50"

RCI 210-DA 300 140

RCI 220-DA 620 290

RCI 230-DA 1150 550

RCI 240-DA 2340 1120

RCIO 250-DA 3630 1720

RCIO 260-DA 7430 3540

RCIO 265-DA 10514 4947

RCIO 270-DA 15040 7260

RCIO 280-DA 30970 14600

60 PSIG AIR SUPPLY 90" Model# o• 50"

105 RCI 210-DA 220 105

220 RCI 220-DA 470 220

425 RCI 230-DA 865 405

865 RCI 240-DA 1750 840

1325 RCIO 250-DA 2725 1285

2745 RCIO 260-DA 5575 2655

3735 RCIO 265-DA 7886 3710

5575 RCIO 270-DA 11280 5440

11500 RCIO 280-DA 23230 10975

100 PSIG AIR SUPPLY

90" Model# o• 50"

220 RCI 210-DA 370 175

450 RCI 220-DA 780 354

850 RCI 230-DA 1430 690

1740 RCI 240-DA 2920 1415

2650 RCIO 250-DA 4510 2170

5490 RCIO 260-DA 9290 4425

7469 RCIO 265-DA 13142 6184

11150 RCIO 270-DA 18805 9070

23010 RCIO 280-DA 38720 18230

90"

170

335

635

1310

1990

4115

5602

8360

17260

90°

265

565

1060

2170

3320

6860

9336

13940

28760

~ REMOTE CONTROL

"-"" Remote Control Inc. • P.O. Box 335 • North Kingstown, Rl 02852

Phone 401-294-1400 • Fax 401-294-3388 • Email [email protected] Website www.rciactuators.com

l ' . ) " i i . ,. • 11: t i ' .i l i ' .. " ~ <i

---· --------- -- ----------~------- -·------------ ------- -----·-----,

I w I I w MANUFACTURING STANDARD I ANsI B 1 6. 34

66 I!J ll NOTES ,'9;_ I j 1 All DIMENSIONS ARE IN INCHES & MIWMETERS. FACE TO FACE TO ANSI 816.10.

1 •• '-a-I! f\J---@ 1 0 / ~ 3. THE FH~ES IJ COOT!Cf F/CE IJ END FINm M WACHNED 115-2511 RNS MTH S£RRI.TED SI'IRII. ANISll.

~ 1 i 4. ANTI-STATIC DEVICES ARE INSTAllED ACCORDING TO BS 5351 I rtJ I )" ~ 2 in.& SWW:R J _ 1:-:::=~ 5. RRE-SAFE DE~IGN, TESTED(API 607, FOURTH EDITION)

1 J I 89 6. ISO Mounbng pad. (ISO 5211) i 22 ~~ 10 ~ ~ 7. Padlocking device, open & closed.

~~ " ~ SIZE 8"&10" TYPE 97 1 \@)

~ 98 Y ' 98 TOP NUT 1 A167-304 65 48 97 TOP BOLT 1 A276-304

~ LOCKING DEVICE 89 LOCKING PLATE BOLT 2 A193-B8 32 J\IUJI ~ 88 LOCKING PLATE 1 A167-304

~ ~~ 1-"; '~ ""' M " ' me " ~"" ''-'"" , ""' , •• ,. ® 1 J!3 I 1 y, 1.971.38 1/4 _ 73 _-+-- _ x 40 49 35 UNC FOS 72 STATIC BALL 1 Set A276-316

22 ~~ ail 2 2.761.38 51,. 71 SPRING 1 Set A276-316 l _,.-- - ~ 4-M TAP so 70 35 UNC F07 66 HANDLE GUIDE 1 A216-WCB '-. ~ m ~ ~~i 2 '1• 4·02 1.38 "" 65 STOPPER 1 A 167-304 " j ~ ~ ~· :.:": "; "' "' """"'' ' '"'"' '"'" ,,;,,,, ""' ~ -~ ! _ ' 80 102 62 UNC F1o 61A HANDLE 1 A536 (DI) 3"& IAAG£R P<illollllue cv-= -1------ r- ---r-- - ~ --- ~lz ~ ~ - ~ @ , • , '·' ,. ,. " '"" ""'"' "'m , A,,_,, ,. , ""' I A "lY. T 100 102 62 UNC F10 49 0-RING *1 N B R

, \.. 1 _1;L l . ,/..,.., 6 4 ·022·76 >I• 48 SNAP RING 2 A686-W1 • ~ ~ '- _l I ' ~ 150 102 70 UNC F10 46 YOKE BOLT 4 A307-B

e--;:r--- I cb rsi~ ~ 1- MOUNTING PAD FOR 1.5' THRU 6' 39 SET SCREW 1 A 1 08-1 020 0---::H-- - 6 49 4 20 - - ~ 32 GLAND BOLT 2 A193-B8

L_--, 25 THRUST WASHER *1 RTFE 15% Glass filled

~~ --= .i ... M ' ~C ~ ) n OW<O '"'"" ,, U"OOOO ,. .. ''"'"'" ;, .... .....!..... ,__§....~ 112 F12 1 ~ 20 GASKET *1 GRAPHITE

L 200 125 UNC F ' 14 SEAT RING •2 RTFE 15% Glass filled 10 5.51 0/8

NPS Bore Fta:TO IIJIIIRTO 01\.0F END FLANGE ~~uNc F14 ' 01 12 YOKE 1 A216-WCB

ln. WJlElER Fta: TOP ~OLE OD ::r OORflr ~W~t~ ¢d 1 Q'TY --/ 11 GLAND FLANGE 1 A351-CF8

mm d L H W D C g T f n-h MOUNTING PAD FOR 8'&10' 1 O GLAND 1 A276-316

! 11/2 1 6.5 4 6 5 3.88 2.87 0.56 .06 1.5 -

0 6 BALL 1 A351-CF8M 4-.63

40 25 165 102 152 127 98.6 73 14.3 1.6 4-16 38 - 5 STEM 1 A276-316

2 1.5 7 5 9 6 4.75 3.62 0.62 .06 4-.75 2 - SEAT 4 CAP 1 A216-WCB

50 38 178 127 230 152 120.5 92 15.9 1.6 4-19 51 - DETAIL 1 BODY 1 A216-WCB 2 1/2 2 7.5 5 9 7 5.50 4.13 0.70 .06 4-.75 2.5 - NO PART NAME Q'TY MATERIAL REMARKS 65 51 190 127 230 178 139.5 105 17.9 1.6 4-19 64 - * Denotes spare parts 3 2.32 8 6.06 13.8 7.5 6 5 0.75 .06 4 .75 3

80 59 203 154 350 191 152.5 127 19.1 1.6 4-19 76 - 3 CLASS .150, CARBON STEEL, BALL VALVE 4 3 9 6.69 13.8 9 7.5 6.19 0.94 .06 8-.75 4 - 2 BOLTED CAP, RF, FULL BORE, FIRE SAFE. !

100 76 229 170 350 229 190.5 157 23.9 1.6 8-19 102 MODEL: U2R150-13RG 6 4.01 10.5 8.11 17.7 11 9.5 8.5 1 .06 8-.88 6 1

150 102 266.7 206 450 279 241.5 216 25.4 1.6 8-22 152 KA.C::::: E "'-./ Cl I -v ~ 8 5.67 11.5 12.76 23.6 13.5 11.75 10.62 1.12 .06 8-.88 8 - 0 NOV.10,01 FOR APPROVAL • SUGAR LAND. TEXAS ;

200 144 292 324 600 343 298.5 270 28.6 1.6 8-22 203 PH:281 -240-0955 FX:281 -240-5619

~'" 7.4 13 13.6 31.5 16 14.25 12.75 1.19 .06 12 1 10 - NO DATE DESCRIPTION PRE'D REV'D APP'D

250 186 330 345 800 406 362 324 30.2 1.6 2-25 254 - DWG NO : U2R150-13RG

---- -- ------------------- ---- ------ --------- ----------- - I

PUMP CONSTRUCTION & SERVICING:

TE-5.5C-MD TE-5.5K-MD

TE-5.55-MD

March "Orbital" Magnetic Drive Pumps eliminate the conventional shaft seals found in most pumps. Hence, there is no rotating shaft or seal to wear and allow the liquid being pumped to leak out. The only seal in the pump is a stationary "0" ring seal between the Front Housing and the Rear Housing. The pump can be serviced with the use of a screwdriver. The only moving part other than the motor, is the Impeller Assembly, which rotates on a stationary shaft and up against a thrust washer. These are the only parts that might wear, and may require replacement. See the Repair Parts List for replacement parts.

H E A D

I N

F E E T

0

40

35

30

25

20

15

10

5

0 0

20 40

- r--

"' -- -.....

' "

TE-5.5C-MD TE-5.5K-MD TE-5.58-MD

L.P.M. 60 80

160HZ I

\ \

\. \ \.

\ lsoHz I ~

\

\

100 120

\ \

\ I\

12

10

8 M E T E

6 R 5

4

2

5 10 15 20 25 30 0

35

On plastic pumps, do not over tighten the 8 Housing Screws (Item 1) or you may L__ __________ G_.P_.M_. _________ _j

crush the plastic Housing bosses. Tighten all screws uniformly.

MODEL ABBREVIATIONS: C = Polypropylene K = Kynar S = Stainless Steel TE =Totally Enclosed Fan Cooled Motor MD = Magnetic Drive

OPERATION: Pumps are not self pnm1ng and will not produce a suction lift and must be installed with a positive flooded suction. We rely on the liquid being pumped to lubricate the Impeller Assembly spinning on the stationary shaft. If the pump is run dry for longer than 30 seconds, the Impeller may "freeze" onto the shaft. A carbon bushing will enable dry running protection. The direction of motor rotation should be clockwise looking at the inlet of the pump. A trimmed impeller may be necessary when pumping a liquid with a specific gravity or viscosity greater than water as well in cases of high liquid temperature.

ELECTRICAL: The standard pump has a TEFC motor, 115/230 Volts, 1 phase or 230/460 Volts, 3 phase rated as continuous duty. A junction box is located on the side of the motor for the electrical hook up.

The wiring instructions are located on the motor label or on the junction box cover. The motor has U.L. yellow card recognition.

Explosion proof and special voltage motors are available upon special order.

SPECIFICATIONS

Max Flow 50Hz lpm 60Hz gpm

Max Head 50Hz m 60Hz ft (psi)

Inlet Outlet

Max Internal psi Pressure bar

Max Liquid "F Temperature "C

Packed Weight kgnbs

Motor Type

Phase Volts

Watts 50Hz Amps

Kw Rpm Volts

Watts 60Hz Amos

Hp Rpm

Electrical Connection

Overall Pump Height Dimensions Width

(Inches) Length Overall Pump Height

Dimensions Width (em) Length

TE-5.5C-MD 110 30 9

41 (17.7)

1"FPT 3/4"MPT

50 3.4 190 87

15.5/34.5

TEFC TEFC 115/230 230/460

1 3 115 230 190 380 290 290 350 350 4.4 2.2 1.2 .6

.248 .248 .186 .186 2850 2850 2850 2850 115 230 230 460 452 452 425 425 4.4 2.2 1.2 .6 1/3 1/3 1/3 1/3

3450 3450 3450 3450 Conduit Box Conduit Box

7.79 7.34 7.65 9.24 14.25 15.07 19.7 18.6 19.4 23.4 36.1 38.2

TE-5.5K-MD TE-5.55-MD 110 110 30 30 9 9

41 (17.7) 41 (17.7)

1"FPT 1"FPT 3/4"MPT 3/4"MPT

75 200 5 13

200 250 93 121

16/35 17.5/39

TEFC TEFC TEFC TEFC 115/230 230/460 115/230 230/460

1 3 1 3 115 230 190 380 115 230 190 380 290 290 350 350 290 290 350 350 4.4 2.2 1.2 .6 4.4 2.2 1.2 .6 .248 .248 .186 .186 .248 .248 .186 .186 2850 2850 2850 2850 2850 2850 2850 2850 115 230 230 460 115 230 230 460 452 452 425 425 452 452 425 425 4.4 2.2 1.2 .6 4.4 2.2 1.2 .6 1/3 1/3 1/3 1/3 1/3 1/3 1/3 1/3

3450 3450 3450 3450 3450 3450 3450 3450 Conduit Box Conduit Box Conduit Box Conduit Box

7.79 7.34 7.79 7.34 7.65 9.24 7.65 9.24 14.25 15.07 14.25 15.07 19.7 18.6 19.7 18.6 19.4 23.4 19.4 23.4 36.1 38.2 36.1 38.2

MATERIALS IN CONTACT WITH SOLUTION: For TE-5.5C-MD: Polypropylene, Viton, Ceramic For TE-5.5K-MD: Kynar/Carbon Filled, Viton, Ceramic

NOTE: When attaching the Drive Magnet Assembly (item 16) to the motor shaft, position the face of the Drive Magnet Assembly flush with the face of the Motor Bracket (item 17).

REPAIR PARTS LIST

For TE-5.5S-MD: 316 Stainless Steel, Viton, Ceramic, Carbon

NOTES: All specifications & data are based on pumping water and are intended for use as a guideline only. Ratings & dimensions may vary depending on the current motor being used.

LIMITED WARRANTY: March pumps are guaranteed only against defects in workmanship or materials for a period of one year from date of manufacture pumping water. On all other solutions, contact the factory for application assistance. March Pump Application Worksheet 0750-0130-1000 is available for additional warranty information.

0151-0026-1000 R11 (Revised 8/20/09)

•

1819 PICKWICK AVE., GLENVIEW, IL 60026·1306, U.S.A PHONE: (847) 729-5300 -FAX: (847) 729·7062 WWW.IIIARCHPUMP.COIII

INSTRUCTIONS & REPAIR PARTS FOR MODELS TE-5.5C-MD, TE-5.5K-MD, AND TE-5.5S-MD

27 23

PUMP CONSTRUCTION & SERVICING March "Orbital" Magnetic Drive Pumps eliminate the conventional shaft seals found in most pumps. This means that there is no rotating shaft or seal to wear and allow the liquid being pumped to leak out. The only seal in the pump is a stationary Viton "0" ring seal between the front and the rear Housings.

The pump can be serviced with the use of a screwdriver. The only moving part in the pump, other than the motor, is the Impeller-Magnet Assembly, which rotates on a stationary ceramic spindle and up against a ceramic thrust washer. These are the only parts that might wear, and may require replacement. See the Repair Parts List for replacement parts.

On plastic pumps, do not over tighten the 8 Housing Screws (Item 13) or you may crush the plastic Housing bosses. Tighten all screws uniformly.

ELECTRICAL AND OPERATION The standard pump has a TEFC motor, 115/230 volts, 60/50 Hz, 1 phase, 3450 r.p.m. rated as continuous duty.

18.2 11.7 1.5 17.5 a 9/16" 7 7/16" 14 7/16"

A junction box is located on the side of the motor for the electrical hook up. The wiring instructions are located on the motor label or on the junction box cover. The motor has U.L. yellow card recognition. We rely on the liquid being pumped to lubricate the Impeller-Magnet assembly bushing spinning on the stationary ceramic spindle. If the pump is run dry for longer than 30 seconds, the Impeller bushing may "freeze" onto the spindle. The direction of motor rotation should be clockwise looking at the inlet of the pump. Other bushing materials are available for "dry" running protection.

Totally enclosed explosion proof and special voltaqe motors are available upon special order.

PUMP MATERIALS The pump components in contact with the liquid are polypropylene, Kynar or type 316 stainless steel. The "0" ring gasket is Viton. The spindle shaft and Thrust Washer are ceramic. The stainless Impeller has a Carbon bushing. Other materials are available on special order.

MODEL TE-5.5C-MD, TE-5.5K-MD, AND TE-5.5S-MD REPAIR PARTS LIST ITEM DESCRIPTION QTY. PART NUMBER

1 Motor, 115/230 Volt, 1 Phase 1 0151-0015-1000 2 Drive Magnet Assembly 1 0151-0061-0100 3 Motor Connecting Bracket 1 0151-0014-0100 4 % I. D. x% 0.0. Stainless Washer 4 0155-0019-1000 5 %-16 x% Long Screw 4 0155-0017-1000

6A Rear Housing (Polyp_ropylene) 1 0151-0028-0100 6B Rear Housing (Kynar) 1 0151-0045-0100 6C Rear Housing, Type 316 Stainless 1 0151-0003-0000 7 Impeller Shaft, Ceramic 1 0153-0007-1 000

SA Impeller Assembly (Polypropylene) 1 0151-0029-0500 8B Impeller Assembly (Kynar) 1 0151-0046-0300 ac Impeller Ass'y., Type 316 S.S. w/Carbon Bushing_ 1 0151-0001-0400 9 Thrust Washer, Ceramic 1 0155-0009-1000 10 4-1!4 1.0. x 3/32 Thick "0" Ring, Viton 1 0153-0015-1000

11A Pump Housing (Polypropylene) 1 0151-0027-1000 11B Pump Housing (Kynar) 1 0151-0044-1000 11C Pump Housing, Type 316 Stainless 1 0151-0002-0000 12 #1 0 Stainless Lock Washer (Stainless Pump Only) 8 0151-0016-1000 13 #1 0-32 x 1 Long Stainless Screw 8 0135-0180-1000

Contact factory for other materials and/or parts not listed.

LIMITED WARRANTY

March pumps are guaranteed only against defects in workmanship or materials for a period of one year from date of manufacture pumping water. On all other solutions, contact the factory for application assistance. March Pump Application Worksheet 750-130-10 is available for additional warranty information.

1819 PICKWICK AVE., GLENVIEW, IL 60026-1306, U.S.A PHONE: (847) 729-5300 · FAX: (847) 729-7062 · www.marchpump.com 0151-0026-1000 R6

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~~E~~~tE ARE • • IDATE I DATE IMOLD ITOOL IFIXTLRE A l JT 110127193

~ 1819 PICKWICK AVE. GLENVIEW, ILLINOIS 05/13/04 05/13/04 NO. NO. NO. REV._jiNITIA~'l_ DATE

Redrawn.

E.C.O. CHANGE

lliM_S. IQl., THIS DOCUMENT DISCLOSED SUBJECT UATTER IN 'M-ilCH MARCH MFG. INC. HAS PROPRIETARY RIGHTS, NEITHER RECEIPT NOR POSSESSION THEREOF CONFERS OR TRANSFERS ANY RIGHT TO REPRODUCE OR CUSTOMER O.OOQ ±O.OOS ~sg~og~ ~T~~C~~~~~u:~J ~~T M~RE~~o:fG~~d.NFORMATlON CONTAINED THEREIN, OR ANY PHYSICAL ARTICLE OR DEVlCE OR TO PRACTICE ANY METHOD OR PROCESS, EXCEPT BY WRITTEN PERMISSION MATERIAL I 0.00 ±0.03

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ASC~ Pilot Operated 3/2•.5/2

D. ct M nt I I. s I ,, L. ..SERIES Ire OU n 1ne poo va1ves .. 8551•: 8553 Anodized Aluminum Bodies • Direct NAMUR Mount ·.. Dilict

1/4" and 1/2" NPT Mount

Features

• Compact spool valve convertible from 3/2 to 5/2

• NAMUR mount construction

• Standard manual operator

• DIN, Watertight and Explosionproof solenoids available

• Single and dual solenoid constructions

• Mountable in any position

• Vents air from spring side of actuator to prevent corrosion of actuator

Construction Valve Parts in Contact with Fluids

Body Black Anodized Aluminum

Spring Phosphate treated black steel

Shading Coil Copper Seals NBR +PUR Core and Core Tube Stainless Steel/ Brass End Covers and Plate 6/6 glass filled PA/FV Spool Aluminum Internal Parts Zamak, Steel, CA

Electrical

Standard Watt Rating and Power Spare Coil

Coil and Consumption Part Number

Class of Enclosure DC AC VA VA Insulation Type Watts Watts Holding Inrush AC DC

F sc 3 2;5 3.5 6 400125 400125

F sc 6.9 5 7 15 43004649 43004647 F EF 6.9 6.3 7 10.1 266762 270007 F WT 6.9 6.3 7 10.1 266763 270008

Standard Voltages: SC: 24, 120, 240 Volts AC, 50-60 Hz; 12, 24, 120 Volts DC. WT and EF: 24/50-60HZ, (120/60, 11 0-120/50)CD, (240/60, 220-240/50)~ Volts AC; 6, 12, 24, 120 Volts DC. CD Order as 120/60, 110/50 ~ Order as 240/60, 220/50

Solenoid Enclosures Standard: - Prefix SC = IP65 type DIN (open frame) per 46244

WT = Combination General Purpose and Watertight Types 1, 2, 3, 3S, 4, and 4X EF = Combination Explosionproof and Watertight Types 3, 3S, 4, 4X, 6, 5P, 7, 9 Class I, Div. 1 (Groups A- D) and Class II, Div. 1 Type 9 (Groups E-G)

8551_1nline_DMoR1

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3/2 5/2

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Nominal Ambient Temp. Ranges SC: AC/DC: SOF to +140°F (-15°C to 60°C) EF: AC: SOF to + 140°F (-15°C to 60°C)

DC: 5°F to +7TF (-15°C to 25°C) WT: AC: 5°F to + 140°F ( -15°C to 60°C)

DC: 5°F to + 7TF ( -15°C to 25°C) Note: For temperatures below 32°F (O"C) moisture-free air must be used. Refer to Engineering Section tor details.

Approvals SC (2.5W and 3W only) UL recognized component, GSA certified. WT: UL recognized component, GSA certified.

EF: ULand GSA solenoid approval. Meets applicable CE directives.

Refer to Engineering Section tor details.

195

3/2•5/2 SERIES 8551,.8553 Direct Mount

Specifications (English units)

Operating Fluid Pressure Temperature •F

Pipe Orifice Cv Differential (psi) (for single and dual solenoid)

Size Size Flow Min. I Max. J M:;· I Max.

(ins.) (ins.) Factor Min. DC OPEN FRAME DIN COIL

.. 1/4 (j) 1/4 .86 30 1 15o 5 1 140 I 140

1/2 1/2 3.7 30 1 15o -15 I 140 I 140

WATERTIGHT ENCLOSURE > .

1/4 (j) 1/4 .86 30 1 15o 5 I 104 I 77

1/2 1/2 3.7 30 I 150 -15 I 140 I 140

EXPLOSIONPROOF ENCLOSURE

1/4 (j) 1/4 .86 30 I 150 5 I 104 I 77

1/2 1/2 3.7 30 I 150 -15 l 140 I 140

Ql 1/8 inch NPT exhausts.

Specifications (Metric units)

Pipe Orifice Size Size (ins.) (mm)

Kv Flow

Factor (m3/h)

Operating Fluid Pressure Temperature ·c

Differential (bar) (for single and dual solenoid)

Min.

Single Solenoid

Catalog Number

SC8551A001 MS

SC8553A001 MS

WT8551 A001 MS

WT8553A001 MS

EF8551A001MS

EF8553A001 MS

Single Solenoid

Catalog Number

SC8551A001MS

SC8553A001 MS

WT8551 A001 MS

WT8553A001 MS

EF8551A001 MS

EF8553A001 MS

196 8551_1nline_DMoR1

ASCG

Watt Rating/ Class of Coil

Dual Solenoid Insulation

Canst. I Catalog Number Ref. AC DC

SC8551 A002MS 1 2.5 I 3

SC8553A002MS 2 5 I 6.9

WT8551 A002MS 1 6.3 I 6.9

WT8553A002MS 2 6.3 I 6.9

EF8551A002MS 1 6.3 I 6.9

EF8553A002MS 2 6.3 I 6.9

WaH Rating/ Class of Coil

Dual Solenoid Insulation

Canst. Catalog Number Ref. AC DC

SC8551 A002MS 3

SC8553A002MS 6.9

WT8551A002MS 6.9

WT8553A002MS 6.9

EF8551A002MS 6.9

EF8553A002MS 6.9 • -

ilfil•

ASC~

Dimensions inches (mm)

Series 8551 NPT 1/4 L1 5.47 (139) L2 7.56 (192) H1 1.30 (33) w 1.77 (45)

NOTE: Valve shown with CM22 DIN terminal coil and connector. Connector sold separately.

Series 8553 NPT 1/2 L1 7.76 (197) L2 10.25 (260) H1 1.94 (49) w 2.85 (72)

NOTE: Valve shown with CM22 DIN terminal coil and connector. Connector sold separately.

t H1

t

H1

t

8551_1nline_DMoR1

Const. Ref. 1

8551 NAMUR Footprint

Con st. Ref. 2

1/2NPT

8553 NAMUR Footprint

3/2•5/2 SERIES

8551,8553 Direct

Mount

197

...

198 8551_1nline_DMoR1

H E

40

35

30

A 25 D

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F

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........ 2.812

' .... ~

12.6871 f"''lll

.... ....,2.5621

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12m 1

TE-5.5C-MD, TE-5.5K-MD 1 PH, 3PH 60HZ

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80 100 120

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SPECIFIC GRAVITY CHART SP.GR. TRIM IMPELLER TO 1.0-1.1-----3.187 DIA. FULL SIZE 1.1-1.2-----3.062 DIA. 1.2-1.3-----2.937 DIA . 1.3-1.4-----2.812 DIA. 1.4-1.5-----2.687 DIA. 1.5-1.6-----2.562 DIA. 1.6-1.8-----2.437 DIA. 1.8-2.0-----2.375 DIA.

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1 PH, 3PH 60HZ

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~------------------------------·----------------------~

lilt··

....

Attention: Mr. Thong Nguyen, Program Manager … Government...The information on this data sheet is...

Documents

Transcript of Attention: Mr. Thong Nguyen, Program Manager … Government...The information on this data sheet is...